CA3172488A1 - Glass-ceramic compositions, articles, and methods of making the same - Google Patents
Glass-ceramic compositions, articles, and methods of making the same Download PDFInfo
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- CA3172488A1 CA3172488A1 CA3172488A CA3172488A CA3172488A1 CA 3172488 A1 CA3172488 A1 CA 3172488A1 CA 3172488 A CA3172488 A CA 3172488A CA 3172488 A CA3172488 A CA 3172488A CA 3172488 A1 CA3172488 A1 CA 3172488A1
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- mol
- glass
- composition
- ceramic composition
- ceramic
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- 239000006112 glass ceramic composition Substances 0.000 title claims abstract description 291
- 238000000034 method Methods 0.000 title claims abstract description 194
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 93
- 229910052642 spodumene Inorganic materials 0.000 claims abstract description 84
- HEHRHMRHPUNLIR-UHFFFAOYSA-N aluminum;hydroxy-[hydroxy(oxo)silyl]oxy-oxosilane;lithium Chemical compound [Li].[Al].O[Si](=O)O[Si](O)=O.O[Si](=O)O[Si](O)=O HEHRHMRHPUNLIR-UHFFFAOYSA-N 0.000 claims abstract description 59
- PAZHGORSDKKUPI-UHFFFAOYSA-N lithium metasilicate Chemical compound [Li+].[Li+].[O-][Si]([O-])=O PAZHGORSDKKUPI-UHFFFAOYSA-N 0.000 claims abstract description 59
- 229910052912 lithium silicate Inorganic materials 0.000 claims abstract description 59
- 229910052670 petalite Inorganic materials 0.000 claims abstract description 59
- 229910052681 coesite Inorganic materials 0.000 claims abstract description 56
- 229910052906 cristobalite Inorganic materials 0.000 claims abstract description 56
- 229910052682 stishovite Inorganic materials 0.000 claims abstract description 56
- 229910052905 tridymite Inorganic materials 0.000 claims abstract description 56
- FUJCRWPEOMXPAD-UHFFFAOYSA-N Li2O Inorganic materials [Li+].[Li+].[O-2] FUJCRWPEOMXPAD-UHFFFAOYSA-N 0.000 claims abstract description 52
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 36
- 235000012239 silicon dioxide Nutrition 0.000 claims abstract description 32
- 239000000203 mixture Substances 0.000 claims description 210
- 239000002241 glass-ceramic Substances 0.000 claims description 101
- 239000013078 crystal Substances 0.000 claims description 98
- 230000008569 process Effects 0.000 claims description 63
- MCMNRKCIXSYSNV-UHFFFAOYSA-N ZrO2 Inorganic materials O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 53
- 238000005342 ion exchange Methods 0.000 claims description 37
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 claims description 35
- 230000001747 exhibiting effect Effects 0.000 claims description 32
- QPLDLSVMHZLSFG-UHFFFAOYSA-N CuO Inorganic materials [Cu]=O QPLDLSVMHZLSFG-UHFFFAOYSA-N 0.000 claims description 28
- 238000002834 transmittance Methods 0.000 claims description 28
- 239000005368 silicate glass Substances 0.000 claims description 24
- HUAUNKAZQWMVFY-UHFFFAOYSA-M sodium;oxocalcium;hydroxide Chemical compound [OH-].[Na+].[Ca]=O HUAUNKAZQWMVFY-UHFFFAOYSA-M 0.000 claims description 21
- 239000000835 fiber Substances 0.000 claims description 19
- 238000010899 nucleation Methods 0.000 claims description 19
- 230000006911 nucleation Effects 0.000 claims description 19
- 150000003839 salts Chemical class 0.000 claims description 18
- 229910000108 silver(I,III) oxide Inorganic materials 0.000 claims description 18
- BERDEBHAJNAUOM-UHFFFAOYSA-N copper(I) oxide Inorganic materials [Cu]O[Cu] BERDEBHAJNAUOM-UHFFFAOYSA-N 0.000 claims description 17
- 238000002425 crystallisation Methods 0.000 claims description 17
- 230000008025 crystallization Effects 0.000 claims description 17
- 239000006025 fining agent Substances 0.000 claims description 17
- 239000000843 powder Substances 0.000 claims description 16
- 238000003279 ceramming Methods 0.000 claims description 14
- 239000006103 coloring component Substances 0.000 claims description 14
- 230000009477 glass transition Effects 0.000 claims description 14
- 238000010438 heat treatment Methods 0.000 claims description 12
- -1 copper (1) ions Chemical class 0.000 claims description 11
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 claims description 10
- KRFJLUBVMFXRPN-UHFFFAOYSA-N cuprous oxide Chemical compound [O-2].[Cu+].[Cu+] KRFJLUBVMFXRPN-UHFFFAOYSA-N 0.000 claims description 10
- VQCBHWLJZDBHOS-UHFFFAOYSA-N erbium(iii) oxide Chemical compound O=[Er]O[Er]=O VQCBHWLJZDBHOS-UHFFFAOYSA-N 0.000 claims description 10
- AMWRITDGCCNYAT-UHFFFAOYSA-L hydroxy(oxo)manganese;manganese Chemical compound [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 claims description 10
- NOTVAPJNGZMVSD-UHFFFAOYSA-N potassium monoxide Inorganic materials [K]O[K] NOTVAPJNGZMVSD-UHFFFAOYSA-N 0.000 claims description 10
- 239000003795 chemical substances by application Substances 0.000 claims description 9
- 238000002844 melting Methods 0.000 claims description 9
- 230000008018 melting Effects 0.000 claims description 9
- 239000011734 sodium Substances 0.000 claims description 9
- 239000002667 nucleating agent Substances 0.000 claims description 8
- 229910052708 sodium Inorganic materials 0.000 claims description 7
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 claims description 6
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 6
- 229910052700 potassium Inorganic materials 0.000 claims description 6
- 229910052709 silver Inorganic materials 0.000 claims description 6
- 239000004332 silver Substances 0.000 claims description 6
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 claims description 5
- 229910000420 cerium oxide Inorganic materials 0.000 claims description 5
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 claims description 5
- 229910000428 cobalt oxide Inorganic materials 0.000 claims description 5
- IVMYJDGYRUAWML-UHFFFAOYSA-N cobalt(ii) oxide Chemical compound [Co]=O IVMYJDGYRUAWML-UHFFFAOYSA-N 0.000 claims description 5
- 239000005357 flat glass Substances 0.000 claims description 5
- 239000005329 float glass Substances 0.000 claims description 5
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 5
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 claims description 5
- 239000011591 potassium Substances 0.000 claims description 5
- 229910001404 rare earth metal oxide Inorganic materials 0.000 claims description 5
- 229940065287 selenium compound Drugs 0.000 claims description 5
- 150000003343 selenium compounds Chemical class 0.000 claims description 5
- 229910052938 sodium sulfate Inorganic materials 0.000 claims description 5
- 235000011152 sodium sulphate Nutrition 0.000 claims description 5
- 239000007921 spray Substances 0.000 claims description 5
- 229910000314 transition metal oxide Inorganic materials 0.000 claims description 5
- 230000000844 anti-bacterial effect Effects 0.000 claims description 4
- 230000000843 anti-fungal effect Effects 0.000 claims description 4
- 230000000845 anti-microbial effect Effects 0.000 claims description 4
- 230000000840 anti-viral effect Effects 0.000 claims description 4
- 238000000137 annealing Methods 0.000 claims description 3
- 239000012035 limiting reagent Substances 0.000 claims description 3
- 238000012681 fiber drawing Methods 0.000 claims description 2
- 238000009987 spinning Methods 0.000 claims description 2
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 claims 2
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 abstract description 23
- 229910052593 corundum Inorganic materials 0.000 abstract description 23
- 229910001845 yogo sapphire Inorganic materials 0.000 abstract description 23
- XUCJHNOBJLKZNU-UHFFFAOYSA-M dilithium;hydroxide Chemical compound [Li+].[Li+].[OH-] XUCJHNOBJLKZNU-UHFFFAOYSA-M 0.000 abstract description 22
- 239000011521 glass Substances 0.000 description 57
- 230000035882 stress Effects 0.000 description 23
- 238000007373 indentation Methods 0.000 description 18
- 150000002500 ions Chemical class 0.000 description 17
- 230000007547 defect Effects 0.000 description 15
- 230000007423 decrease Effects 0.000 description 14
- 239000006104 solid solution Substances 0.000 description 13
- 238000000113 differential scanning calorimetry Methods 0.000 description 11
- 238000002441 X-ray diffraction Methods 0.000 description 10
- 239000000463 material Substances 0.000 description 7
- 239000007788 liquid Substances 0.000 description 6
- 239000005398 lithium aluminium silicate glass-ceramic Substances 0.000 description 6
- 238000010587 phase diagram Methods 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- 229910007562 Li2SiO3 Inorganic materials 0.000 description 5
- 238000001816 cooling Methods 0.000 description 5
- KRHYYFGTRYWZRS-UHFFFAOYSA-N Fluorane Chemical compound F KRHYYFGTRYWZRS-UHFFFAOYSA-N 0.000 description 4
- 230000004913 activation Effects 0.000 description 4
- 230000004888 barrier function Effects 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 230000008859 change Effects 0.000 description 4
- 230000003247 decreasing effect Effects 0.000 description 4
- 238000007496 glass forming Methods 0.000 description 4
- 239000010453 quartz Substances 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N titanium dioxide Inorganic materials O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 4
- 229910000272 alkali metal oxide Inorganic materials 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 239000000919 ceramic Substances 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- 230000002349 favourable effect Effects 0.000 description 3
- 230000000670 limiting effect Effects 0.000 description 3
- 238000012417 linear regression Methods 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 230000007246 mechanism Effects 0.000 description 3
- 229910044991 metal oxide Inorganic materials 0.000 description 3
- 238000007493 shaping process Methods 0.000 description 3
- RZVAJINKPMORJF-UHFFFAOYSA-N Acetaminophen Chemical compound CC(=O)NC1=CC=C(O)C=C1 RZVAJINKPMORJF-UHFFFAOYSA-N 0.000 description 2
- 239000006018 Li-aluminosilicate Substances 0.000 description 2
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 2
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 2
- 239000000404 calcium aluminium silicate Substances 0.000 description 2
- 235000012215 calcium aluminium silicate Nutrition 0.000 description 2
- WNCYAPRTYDMSFP-UHFFFAOYSA-N calcium aluminosilicate Chemical compound [Al+3].[Al+3].[Ca+2].[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O WNCYAPRTYDMSFP-UHFFFAOYSA-N 0.000 description 2
- 229940078583 calcium aluminosilicate Drugs 0.000 description 2
- 229910001385 heavy metal Inorganic materials 0.000 description 2
- 238000002354 inductively-coupled plasma atomic emission spectroscopy Methods 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- 229910052744 lithium Inorganic materials 0.000 description 2
- XGZVUEUWXADBQD-UHFFFAOYSA-L lithium carbonate Chemical compound [Li+].[Li+].[O-]C([O-])=O XGZVUEUWXADBQD-UHFFFAOYSA-L 0.000 description 2
- 229910052808 lithium carbonate Inorganic materials 0.000 description 2
- 229910021645 metal ion Inorganic materials 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 239000006064 precursor glass Substances 0.000 description 2
- 238000012552 review Methods 0.000 description 2
- 239000006133 sodium aluminosilicate glass Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- JTEJPPKMYBDEMY-UHFFFAOYSA-N 5-methoxytryptamine Chemical compound COC1=CC=C2NC=C(CCN)C2=C1 JTEJPPKMYBDEMY-UHFFFAOYSA-N 0.000 description 1
- 238000007088 Archimedes method Methods 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- CPELXLSAUQHCOX-UHFFFAOYSA-M Bromide Chemical compound [Br-] CPELXLSAUQHCOX-UHFFFAOYSA-M 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910002483 Cu Ka Inorganic materials 0.000 description 1
- JPVYNHNXODAKFH-UHFFFAOYSA-N Cu2+ Chemical compound [Cu+2] JPVYNHNXODAKFH-UHFFFAOYSA-N 0.000 description 1
- 229910008556 Li2O—Al2O3—SiO2 Inorganic materials 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 238000006124 Pilkington process Methods 0.000 description 1
- 101100234556 Saccharomyces cerevisiae (strain ATCC 204508 / S288c) KOG1 gene Proteins 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 1
- 238000007545 Vickers hardness test Methods 0.000 description 1
- 239000006094 Zerodur Substances 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 229910001413 alkali metal ion Inorganic materials 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 229940121375 antifungal agent Drugs 0.000 description 1
- 229910052788 barium Inorganic materials 0.000 description 1
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 229910052792 caesium Inorganic materials 0.000 description 1
- TVFDJXOCXUVLDH-UHFFFAOYSA-N caesium atom Chemical compound [Cs] TVFDJXOCXUVLDH-UHFFFAOYSA-N 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- PBAYDYUZOSNJGU-UHFFFAOYSA-N chelidonic acid Natural products OC(=O)C1=CC(=O)C=C(C(O)=O)O1 PBAYDYUZOSNJGU-UHFFFAOYSA-N 0.000 description 1
- 238000004040 coloring Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 229910001431 copper ion Inorganic materials 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000004031 devitrification Methods 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 239000012153 distilled water Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000003280 down draw process Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005684 electric field Effects 0.000 description 1
- 238000000635 electron micrograph Methods 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 229910000174 eucryptite Inorganic materials 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 238000007667 floating Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 235000013305 food Nutrition 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 238000003286 fusion draw glass process Methods 0.000 description 1
- 239000000156 glass melt Substances 0.000 description 1
- 150000004820 halides Chemical class 0.000 description 1
- 238000000265 homogenisation Methods 0.000 description 1
- XMBWDFGMSWQBCA-UHFFFAOYSA-N hydrogen iodide Chemical compound I XMBWDFGMSWQBCA-UHFFFAOYSA-N 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000006060 molten glass Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 150000002823 nitrates Chemical class 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 230000008520 organization Effects 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 238000013001 point bending Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000005297 pyrex Substances 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 229910052701 rubidium Inorganic materials 0.000 description 1
- IGLNJRXAVVLDKE-UHFFFAOYSA-N rubidium atom Chemical compound [Rb] IGLNJRXAVVLDKE-UHFFFAOYSA-N 0.000 description 1
- JBYXPOFIGCOSSB-UQGDGPGGSA-N rumenic acid Chemical compound CCCCCC\C=C/C=C/CCCCCCCC(O)=O JBYXPOFIGCOSSB-UQGDGPGGSA-N 0.000 description 1
- 238000003283 slot draw process Methods 0.000 description 1
- 229910000029 sodium carbonate Inorganic materials 0.000 description 1
- 235000017550 sodium carbonate Nutrition 0.000 description 1
- 238000003980 solgel method Methods 0.000 description 1
- 238000001228 spectrum Methods 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 239000013526 supercooled liquid Substances 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 230000000930 thermomechanical effect Effects 0.000 description 1
- 238000007668 thin rolling process Methods 0.000 description 1
- 238000002371 ultraviolet--visible spectrum Methods 0.000 description 1
- 238000001392 ultraviolet--visible--near infrared spectroscopy Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C10/00—Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition
- C03C10/0018—Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition containing SiO2, Al2O3 and monovalent metal oxide as main constituents
- C03C10/0027—Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition containing SiO2, Al2O3 and monovalent metal oxide as main constituents containing SiO2, Al2O3, Li2O as main constituents
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47J—KITCHEN EQUIPMENT; COFFEE MILLS; SPICE MILLS; APPARATUS FOR MAKING BEVERAGES
- A47J36/00—Parts, details or accessories of cooking-vessels
- A47J36/02—Selection of specific materials, e.g. heavy bottoms with copper inlay or with insulating inlay
- A47J36/04—Selection of specific materials, e.g. heavy bottoms with copper inlay or with insulating inlay the materials being non-metallic
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B25/00—Annealing glass products
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B32/00—Thermal after-treatment of glass products not provided for in groups C03B19/00, C03B25/00 - C03B31/00 or C03B37/00, e.g. crystallisation, eliminating gas inclusions or other impurities; Hot-pressing vitrified, non-porous, shaped glass products
- C03B32/02—Thermal crystallisation, e.g. for crystallising glass bodies into glass-ceramic articles
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C1/00—Ingredients generally applicable to manufacture of glasses, glazes, or vitreous enamels
- C03C1/004—Refining agents
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C10/00—Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition
- C03C10/0054—Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition containing PbO, SnO2, B2O3
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C13/00—Fibre or filament compositions
- C03C13/006—Glass-ceramics fibres
- C03C13/007—Glass-ceramics fibres containing zirconium
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C21/00—Treatment of glass, not in the form of fibres or filaments, by diffusing ions or metals in the surface
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C3/00—Glass compositions
- C03C3/04—Glass compositions containing silica
- C03C3/076—Glass compositions containing silica with 40% to 90% silica, by weight
- C03C3/083—Glass compositions containing silica with 40% to 90% silica, by weight containing aluminium oxide or an iron compound
- C03C3/085—Glass compositions containing silica with 40% to 90% silica, by weight containing aluminium oxide or an iron compound containing an oxide of a divalent metal
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C4/00—Compositions for glass with special properties
- C03C4/02—Compositions for glass with special properties for coloured glass
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47G—HOUSEHOLD OR TABLE EQUIPMENT
- A47G19/00—Table service
- A47G19/02—Plates, dishes or the like
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47G—HOUSEHOLD OR TABLE EQUIPMENT
- A47G2400/00—Details not otherwise provided for in A47G19/00-A47G23/16
- A47G2400/10—Articles made from a particular material
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C2204/00—Glasses, glazes or enamels with special properties
- C03C2204/04—Opaque glass, glaze or enamel
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Abstract
Disclosed herein are glass-ceramic compositions, articles made from the disclosed glass-ceramic compositions, and methods of making the same. More specifically disclosed herein is a glass-ceramic composition comprising: a) from about 2 mol% to about 20 mol% of Al2O3; b) from about 2 mol% to about 45 mol% of Li2O; and c) from about 48 mol% to about 80 mol% of SiO2; having a ?-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase.
Description
GLASS-CERAMIC COMPOSITIONS, ARTICLES, AND METHODS OF MAKING
THE SAME
CROSS-REFERENCE TO RELATED APPLICATIONS
Ll] This application claims the benefit of priority to U.S
Provisional Application No. 63/057,404, filed July 28, 2020, the content of which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
[23 The present invention generally relates to glass-ceramic compositions, glass-ceramic articles comprising the same, and methods of making the same.
BACKGROUND
[3] Glass-ceramics, nucleated and crystallized from a certain composition of glass, are known for their low thermal expansion, high mechanical strength, and good thermal stability. Glass-ceramics, such as Li2O-A1203-SiO2 (LAS) systems, combine the advantages of near-zero thermal expansion and good transparency, together with high fracture toughness and ion-exchange potential. It is known that Li2O-A1203-SiO2 glass-ceramics can contain different phases, such asp-quartz solid solution and p-spodumene solid solution, or petalite It is also known that the properties of the glass-ceramic compositions are strongly dependent on their phase composition.
[4] It was shown in the past that the glass-ceramics could be designed with near-zero thermal expansion over a large temperature range by balancing the amount of negative expansion of the 13-quartz and positive expansion of the residue glass. Many commercial glass-ceramics (Vision (Corning [11-12]), Zerodur, and Ceran (Schott [13-17]), Narumi and NeoceramTM N=0 (NipponElectric [18-19])) containing 13-quartz crystals have been used to make radiant cooktops, transparent cookware, woodstove windows, and fire doors.
Es] The f3-spodumene solid solutions formed when the 13-quartz is heated at 850 C for eight hours. Coming Ware 9608, containing p-spodumene main phase and rutile minor phase, is a well-known glass-ceramics used for low-cost kitchen applications. However, most of the 13-spodumene glass-ceramics are opaque, as they crystallize at relatively high temperature and low viscosity.
[6] Accordingly, a need exists for alternative glass-ceramics compositions having improved mechanical properties while exhibiting transparent, opaque, or translucent properties, depending on a specified need. These needs and other needs are at least partially satisfied by the present disclosure.
SUMMARY
[7] The present invention is directed to a glass-ceramic composition comprising:
a) from about 2 mol% to about 20 mol% of A1203; b) from about 2 mol% to about mol% of L120; and c) from about 48 mol% to about 80 mol% of Si02; having a 1:3-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase. In yet further aspects, when A1203 is present from about 5 mol% to about 7.5 mol 0/0, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase and from about 20 to about 80% of the petalite phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase. While yet in other aspects, when A1203 is present from about 7 mol% to about 12 mol /0, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the fl-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
[8] In still further aspects, the disclosed glass-ceramic compositions can further comprise: a) from 0 mol% to about 8 mol% of 8203, b) from 0 mol% to about 8 mol%
of Zr02, c) from 0 mol% to about 5 mo10/0 of P205, and d) from 0 mol% to about mol% of Na20.
[9] Also disclosed herein is a glass-ceramic composition comprising: a) present from about 2 mol% to about 20 mol%, b) Si02 present from about 48 mol%
to about 80 mol%, c) R'20 present from greater than 0 mol% to about 45 mol%;
and wherein R'20 comprises Li20, Na20, 1<20, Ag20, Cu2O, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a 13-spodumene phase, and optionally, a petalite phase. In such exemplary aspects, when A1203 is present from about 5 mol% to about 7.5 mol %, the glass-ceramic
THE SAME
CROSS-REFERENCE TO RELATED APPLICATIONS
Ll] This application claims the benefit of priority to U.S
Provisional Application No. 63/057,404, filed July 28, 2020, the content of which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
[23 The present invention generally relates to glass-ceramic compositions, glass-ceramic articles comprising the same, and methods of making the same.
BACKGROUND
[3] Glass-ceramics, nucleated and crystallized from a certain composition of glass, are known for their low thermal expansion, high mechanical strength, and good thermal stability. Glass-ceramics, such as Li2O-A1203-SiO2 (LAS) systems, combine the advantages of near-zero thermal expansion and good transparency, together with high fracture toughness and ion-exchange potential. It is known that Li2O-A1203-SiO2 glass-ceramics can contain different phases, such asp-quartz solid solution and p-spodumene solid solution, or petalite It is also known that the properties of the glass-ceramic compositions are strongly dependent on their phase composition.
[4] It was shown in the past that the glass-ceramics could be designed with near-zero thermal expansion over a large temperature range by balancing the amount of negative expansion of the 13-quartz and positive expansion of the residue glass. Many commercial glass-ceramics (Vision (Corning [11-12]), Zerodur, and Ceran (Schott [13-17]), Narumi and NeoceramTM N=0 (NipponElectric [18-19])) containing 13-quartz crystals have been used to make radiant cooktops, transparent cookware, woodstove windows, and fire doors.
Es] The f3-spodumene solid solutions formed when the 13-quartz is heated at 850 C for eight hours. Coming Ware 9608, containing p-spodumene main phase and rutile minor phase, is a well-known glass-ceramics used for low-cost kitchen applications. However, most of the 13-spodumene glass-ceramics are opaque, as they crystallize at relatively high temperature and low viscosity.
[6] Accordingly, a need exists for alternative glass-ceramics compositions having improved mechanical properties while exhibiting transparent, opaque, or translucent properties, depending on a specified need. These needs and other needs are at least partially satisfied by the present disclosure.
SUMMARY
[7] The present invention is directed to a glass-ceramic composition comprising:
a) from about 2 mol% to about 20 mol% of A1203; b) from about 2 mol% to about mol% of L120; and c) from about 48 mol% to about 80 mol% of Si02; having a 1:3-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase. In yet further aspects, when A1203 is present from about 5 mol% to about 7.5 mol 0/0, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase and from about 20 to about 80% of the petalite phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase. While yet in other aspects, when A1203 is present from about 7 mol% to about 12 mol /0, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the fl-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
[8] In still further aspects, the disclosed glass-ceramic compositions can further comprise: a) from 0 mol% to about 8 mol% of 8203, b) from 0 mol% to about 8 mol%
of Zr02, c) from 0 mol% to about 5 mo10/0 of P205, and d) from 0 mol% to about mol% of Na20.
[9] Also disclosed herein is a glass-ceramic composition comprising: a) present from about 2 mol% to about 20 mol%, b) Si02 present from about 48 mol%
to about 80 mol%, c) R'20 present from greater than 0 mol% to about 45 mol%;
and wherein R'20 comprises Li20, Na20, 1<20, Ag20, Cu2O, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a 13-spodumene phase, and optionally, a petalite phase. In such exemplary aspects, when A1203 is present from about 5 mol% to about 7.5 mol %, the glass-ceramic
2 composition comprises a major crystalline phase comprising from about 20 to about 80% of the J3-spodumene phase and from about 20 to about 80% of the petalite phase. While in yet other aspects, when A1203 is present from about 5 mol% to about 7.5 mol % and Li20 is present from 20 mo10/0 to about 25 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase and from about 20 to about 80% of the petalite phase, and a minor phase comprises up to 10 mol% of the lithium silicate phase. In still further aspects, such compositions can further comprise: a) B203 present from 0 mol% to about 8 mol%, b) Zr02 from 0 mo10/0 to about 8 mol%, and c) P205 from mol% to about 5 mol%. In still further aspects, the disclosed herein compositions can comprise a compressive stress layer.
[10] Also disclosed herein is a glass-ceramic article comprising any of the preceding compositions. In certain aspects, also disclosed is a glass-ceramic article comprising compositions having a compressive stress layer. In such exemplary aspects, disclosed are articles where the compressive stress layer extends from a surface of the article to a depth of the compressive stress layer, and wherein the depth is from about 1 pm to about 100 pm.
[11] Also is disclosed a glass-ceramic article comprising: a) from about 2 mo10/0 to about 20 mol% of A1203, b) Si02 present from about 48 mol% to about 80 mol%;
and R'20 present from greater than 0 mol% to about 45 mol%: wherein R'20 comprises Li20, Na20, K20, Ag20, Cu20, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase. The articles disclosed herein can comprise a hollowware, tableware, container, plate, sheet, float/flat sheet, cookware, powder, fiber, cones, spheres, blades, or any combination thereof. In still further aspects, the articles disclosed herein can be formed by a float or flat glass press process, a press-and-blow process, a blow-and-blow process, or any combination thereof.
[12] Also disclosed herein are methods comprising: a) forming a mixture comprising from about 2 mol% to about 20 mol% of A1203, from about 2 mol% to about 45 mol% of Li20; and from about 48 mol% to about 80 mol% of Si02; b) forming a homogeneous composition; and c) cerarnming the homogeneous composition to form a glass-ceramic composition. In yet further aspects, the methods
[10] Also disclosed herein is a glass-ceramic article comprising any of the preceding compositions. In certain aspects, also disclosed is a glass-ceramic article comprising compositions having a compressive stress layer. In such exemplary aspects, disclosed are articles where the compressive stress layer extends from a surface of the article to a depth of the compressive stress layer, and wherein the depth is from about 1 pm to about 100 pm.
[11] Also is disclosed a glass-ceramic article comprising: a) from about 2 mo10/0 to about 20 mol% of A1203, b) Si02 present from about 48 mol% to about 80 mol%;
and R'20 present from greater than 0 mol% to about 45 mol%: wherein R'20 comprises Li20, Na20, K20, Ag20, Cu20, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase. The articles disclosed herein can comprise a hollowware, tableware, container, plate, sheet, float/flat sheet, cookware, powder, fiber, cones, spheres, blades, or any combination thereof. In still further aspects, the articles disclosed herein can be formed by a float or flat glass press process, a press-and-blow process, a blow-and-blow process, or any combination thereof.
[12] Also disclosed herein are methods comprising: a) forming a mixture comprising from about 2 mol% to about 20 mol% of A1203, from about 2 mol% to about 45 mol% of Li20; and from about 48 mol% to about 80 mol% of Si02; b) forming a homogeneous composition; and c) cerarnming the homogeneous composition to form a glass-ceramic composition. In yet further aspects, the methods
3 disclosed herein further comprise a step of ion-exchange treatment comprising placing the glass-ceramic composition into a molten salt bath comprising sodium, potassium, silver, or copper (I) ions or a combination thereof at conditions effective to provide an ion-exchanged glass-ceramic composition. In such exemplary aspects, the formed the ion-exchanged glass-ceramic composition comprises: a) A1203 present from about 2 mol% to about 20 mol%; b) SiO2 present from about 48 mol%
to about 80 mol%; c) R'20 present from greater than 0 mol% to about 45 mol%;
and wherein R'20 comprises Li2O, Na2O, K2O, Ag2O, Cu2O, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a ii-spodumene phase, and optionally, a petalite phase.
OM Also disclosed herein are methods of forming an article comprising forming any of the disclosed above compositions and then forming the article, wherein the article comprises a hollowware, tableware, container, plate, sheet, float or flat sheet, cookware, powder, fiber, cones, spheres. blades, or any combination thereof.
In still further aspects, the step of forming the glass-ceramic articles comprises a float or flat press process, a press-and-blow process, a blow-and-blow process, or any combination thereof.
to about 80 mol%; c) R'20 present from greater than 0 mol% to about 45 mol%;
and wherein R'20 comprises Li2O, Na2O, K2O, Ag2O, Cu2O, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a ii-spodumene phase, and optionally, a petalite phase.
OM Also disclosed herein are methods of forming an article comprising forming any of the disclosed above compositions and then forming the article, wherein the article comprises a hollowware, tableware, container, plate, sheet, float or flat sheet, cookware, powder, fiber, cones, spheres. blades, or any combination thereof.
In still further aspects, the step of forming the glass-ceramic articles comprises a float or flat press process, a press-and-blow process, a blow-and-blow process, or any combination thereof.
04] Additional aspects of the disclosure will be set forth, in part, in the detailed description, figures, and claims which follow, and in part will be derived from the detailed description, or can be learned by practice of the invention. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as disclosed.
BRIEF DESCRIPTION OF DRAWINGS
BRIEF DESCRIPTION OF DRAWINGS
5] FIGURE 1 shows the phase diagram of Li2O-Al2O3-SiO2 (according to reference [6]).
[16] FIGURES 2A-2B depict XRD patterns: FIG. 2A shows an XRD
pattern of exemplary glass-ceramics, with petalite and LiAlSi308 as the main two phases, and Li2SiO3 as a minor phase; FIG. 2B shows an exemplary XRD pattern of other exemplary glass-ceramics. VVhen Al2O3 in the composition is too high, the formation of the LiAlSi308 phase is favorable. When A1203 is too low in the composition, the formation of the Li2SiO3 phase is favorable. When S102 is too high in the composition, the formation of the SiO2 phase is favorable [17] FIGURES 3A-38 depict DSC patterns: FIG. 3A shows an exemplary DSC
pattern of samples with different amounts of Li2O and A1203. FIG. 38 shows glass transition temperature (To) change with a change in the weight percent of Al2O3.
[18] FIGURE 4 shows the phase diagram of LiA102-SiO2, indicating the ranges of petalite and P-spodumene phases (according to reference [251).
[19] FIGURE 5A depicts a viscosity-temperature curve of LAS10, LAS11, and a standard soda-lime silicate glass (SG80): FIGURE 5B depicts a MYEGA fitting of LAS11 sample.
[20] FIGURE 6 depicts a density of exemplary glass samples with the amount of ZrO2.
[21] FIGURE 7 depicts the transmittance of different exemplary glass-ceramics samples.
[22] FIGURES 8A-8C depict secondary electron micrographs images of opaque (FIG. 8A), translucent (FIG. 88), and transparent (FIG. 8C) exemplary LAS
glass-ceramics from SEM.
[23] FIGURES 9A-9B depicts crack probabilities of different exemplary glass-ceramic samples under different loads.
[24] FIGURE 10 depicts a CTE of exemplary LAS11 glass and glass-ceramics samples.
DETAILED DESCRIPTION
[25] The present invention can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present articles, systems, and/or methods are disclosed and described, it is to be understood that this invention is not limited to the specific or exemplary aspects of articles, systems, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.
[261 The following description of the invention is provided as an enabling teaching of the invention in its best, currently known aspect To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features.
Accordingly, those of ordinary skill in the pertinent art will recognize that many modifications and adaptations to the present invention are possible and may even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is again provided as illustrative of the principles of the present invention and not in limitation thereof.
DEFINITIONS
(271 As used herein, the singular forms "a," "an," and "the"
include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to an "article" includes aspects having two or more such articles unless the context clearly indicates otherwise.
(28] It is appreciated that certain features of the disclosure, which are, for clarity, described in the context of separate aspects, can also be provided in combination in a single aspect. Conversely, various features of the disclosure, which are, for brevity, described in the context of a single aspect, can also be provided separately or in any suitable combination.
[29] As used herein, the terms "optional" or "optionally" mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
(30] It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term "comprising" can include the aspects "consisting of and "consisting essentially of." Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly
[16] FIGURES 2A-2B depict XRD patterns: FIG. 2A shows an XRD
pattern of exemplary glass-ceramics, with petalite and LiAlSi308 as the main two phases, and Li2SiO3 as a minor phase; FIG. 2B shows an exemplary XRD pattern of other exemplary glass-ceramics. VVhen Al2O3 in the composition is too high, the formation of the LiAlSi308 phase is favorable. When A1203 is too low in the composition, the formation of the Li2SiO3 phase is favorable. When S102 is too high in the composition, the formation of the SiO2 phase is favorable [17] FIGURES 3A-38 depict DSC patterns: FIG. 3A shows an exemplary DSC
pattern of samples with different amounts of Li2O and A1203. FIG. 38 shows glass transition temperature (To) change with a change in the weight percent of Al2O3.
[18] FIGURE 4 shows the phase diagram of LiA102-SiO2, indicating the ranges of petalite and P-spodumene phases (according to reference [251).
[19] FIGURE 5A depicts a viscosity-temperature curve of LAS10, LAS11, and a standard soda-lime silicate glass (SG80): FIGURE 5B depicts a MYEGA fitting of LAS11 sample.
[20] FIGURE 6 depicts a density of exemplary glass samples with the amount of ZrO2.
[21] FIGURE 7 depicts the transmittance of different exemplary glass-ceramics samples.
[22] FIGURES 8A-8C depict secondary electron micrographs images of opaque (FIG. 8A), translucent (FIG. 88), and transparent (FIG. 8C) exemplary LAS
glass-ceramics from SEM.
[23] FIGURES 9A-9B depicts crack probabilities of different exemplary glass-ceramic samples under different loads.
[24] FIGURE 10 depicts a CTE of exemplary LAS11 glass and glass-ceramics samples.
DETAILED DESCRIPTION
[25] The present invention can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present articles, systems, and/or methods are disclosed and described, it is to be understood that this invention is not limited to the specific or exemplary aspects of articles, systems, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.
[261 The following description of the invention is provided as an enabling teaching of the invention in its best, currently known aspect To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features.
Accordingly, those of ordinary skill in the pertinent art will recognize that many modifications and adaptations to the present invention are possible and may even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is again provided as illustrative of the principles of the present invention and not in limitation thereof.
DEFINITIONS
(271 As used herein, the singular forms "a," "an," and "the"
include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to an "article" includes aspects having two or more such articles unless the context clearly indicates otherwise.
(28] It is appreciated that certain features of the disclosure, which are, for clarity, described in the context of separate aspects, can also be provided in combination in a single aspect. Conversely, various features of the disclosure, which are, for brevity, described in the context of a single aspect, can also be provided separately or in any suitable combination.
[29] As used herein, the terms "optional" or "optionally" mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
(30] It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term "comprising" can include the aspects "consisting of and "consisting essentially of." Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly
6
7 understood by one of ordinary skill in the art to which this invention belongs. In this specification and in the claims, which follow, reference will be made to a number of terms that shall be defined herein.
[31] For the terms "for example" and "such as," and grammatical equivalences thereof, the phrase "and without limitation" is understood to follow unless explicitly stated otherwise.
[32] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Furthermore, when numerical ranges of varying scope are set forth herein, it is contemplated that any combination of these values inclusive of the recited values may be used.
Further, ranges can be expressed herein as from "about" one particular value and/or to "about" another particular value. Wien such a range is expressed, another aspect includes from the one particular value and/or to the other particular value.
(33] Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint and independently of the other endpoint. Unless stated otherwise, the term "about" means within 5% (e.g., within 2% or 1%) of the particular value modified by the term "about."
(34] Throughout this disclosure, various aspects of the invention can be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 toe, etc., as well as individual numbers within that range, for example, 1, 2, 2.7, 3, 4, 5, 5.3, 6 and any whole and partial increments therebetween. This applies regardless of the breadth of the range.
1:35] As used herein, the term "composition" is intended to encompass a product comprising the specified ingredients in the specified amounts, as well as any product which results, directly or indirectly, from a combination of the specified ingredients in the specified amounts.
[36] A weight percent (wt.%) of a component, unless specifically stated to the contrary, is based on the total weight of the formulation or composition in which the component is included. In the aspects where the glass compositions are described, the concentration of constituent components (e.g., SiO2, A1203, B203, and the like) are given in a mole percent (mo16/0) on an oxide basis, unless otherwise specified.
[37] It will be understood that when an element is referred to as being "connected" or "coupled" to another element, it can be directly connected or coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements present. Other words used to describe the relationship between elements or layers should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," "on"
versus "directly on"). As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
[38] It will be understood that, although the terms "first," "second,"
etc., may be used herein to describe various elements, components, regions, layers, and/or sections. These elements, components, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another element, component, region, layer, or a section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of example embodiments.
[39] Spatially relative terms, such as "beneath," "below," "lower,"
"above,"
"upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in
[31] For the terms "for example" and "such as," and grammatical equivalences thereof, the phrase "and without limitation" is understood to follow unless explicitly stated otherwise.
[32] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Furthermore, when numerical ranges of varying scope are set forth herein, it is contemplated that any combination of these values inclusive of the recited values may be used.
Further, ranges can be expressed herein as from "about" one particular value and/or to "about" another particular value. Wien such a range is expressed, another aspect includes from the one particular value and/or to the other particular value.
(33] Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint and independently of the other endpoint. Unless stated otherwise, the term "about" means within 5% (e.g., within 2% or 1%) of the particular value modified by the term "about."
(34] Throughout this disclosure, various aspects of the invention can be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 toe, etc., as well as individual numbers within that range, for example, 1, 2, 2.7, 3, 4, 5, 5.3, 6 and any whole and partial increments therebetween. This applies regardless of the breadth of the range.
1:35] As used herein, the term "composition" is intended to encompass a product comprising the specified ingredients in the specified amounts, as well as any product which results, directly or indirectly, from a combination of the specified ingredients in the specified amounts.
[36] A weight percent (wt.%) of a component, unless specifically stated to the contrary, is based on the total weight of the formulation or composition in which the component is included. In the aspects where the glass compositions are described, the concentration of constituent components (e.g., SiO2, A1203, B203, and the like) are given in a mole percent (mo16/0) on an oxide basis, unless otherwise specified.
[37] It will be understood that when an element is referred to as being "connected" or "coupled" to another element, it can be directly connected or coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements present. Other words used to describe the relationship between elements or layers should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," "on"
versus "directly on"). As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
[38] It will be understood that, although the terms "first," "second,"
etc., may be used herein to describe various elements, components, regions, layers, and/or sections. These elements, components, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another element, component, region, layer, or a section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of example embodiments.
[39] Spatially relative terms, such as "beneath," "below," "lower,"
"above,"
"upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in
8 the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations), and the spatially relative descriptors used herein interpreted accordingly.
[40] As used herein, the term "substantially" means that the subsequently described event or circumstance completely occurs or that the subsequently described event or circumstance generally, typically, or approximately occurs.
[41] Still further, the term "substantially" can in some aspects refer to at least about 80 %, at least about 85 %, at least about 90 %, at least about 91 %, at least about 92 %, at least about 93 /0, at least about 94 %, at least about 95 %, at least about 96 %, at least about 97 %, at least about 98 A), at least about 99 %, or about 100 A) of the stated property, component, composition, or other condition for which substantially is used to characterize or otherwise quantify an amount.
[42] In other aspects, as used herein, the term "substantially free," when used in the context of a composition or component of a composition that is substantially absent, is intended to indicate that the recited component is not intentionally batched and added to the composition, but can be present as an impurity along with other components being added to the composition. In such aspects, the term "substantially free" is intended to refer to trace amounts that can be present in the batched components, for example, it can be present in an amount that is less than about 1 %
by weight, e.g., less than about 0.5 % by weight, less than about 0.1 A) by weight, less than about 0.05 % by weight, or less than about 0.01 % by weight of the stated material, based on the total weight of the composition.
[43] In other aspects, as used herein, the term "substantially free," when used in the context of a surface substantially free of defects, for example, is intended to refer to a surface that has less than about 5 % of defects, less than about 4.5 % of defects, less than about 4 % of defects, less than about 3.5 % of defects, less than about 3 % of defects, less than about 2.5 % of defects, less than about 2 % of
[40] As used herein, the term "substantially" means that the subsequently described event or circumstance completely occurs or that the subsequently described event or circumstance generally, typically, or approximately occurs.
[41] Still further, the term "substantially" can in some aspects refer to at least about 80 %, at least about 85 %, at least about 90 %, at least about 91 %, at least about 92 %, at least about 93 /0, at least about 94 %, at least about 95 %, at least about 96 %, at least about 97 %, at least about 98 A), at least about 99 %, or about 100 A) of the stated property, component, composition, or other condition for which substantially is used to characterize or otherwise quantify an amount.
[42] In other aspects, as used herein, the term "substantially free," when used in the context of a composition or component of a composition that is substantially absent, is intended to indicate that the recited component is not intentionally batched and added to the composition, but can be present as an impurity along with other components being added to the composition. In such aspects, the term "substantially free" is intended to refer to trace amounts that can be present in the batched components, for example, it can be present in an amount that is less than about 1 %
by weight, e.g., less than about 0.5 % by weight, less than about 0.1 A) by weight, less than about 0.05 % by weight, or less than about 0.01 % by weight of the stated material, based on the total weight of the composition.
[43] In other aspects, as used herein, the term "substantially free," when used in the context of a surface substantially free of defects, for example, is intended to refer to a surface that has less than about 5 % of defects, less than about 4.5 % of defects, less than about 4 % of defects, less than about 3.5 % of defects, less than about 3 % of defects, less than about 2.5 % of defects, less than about 2 % of
9 defects, less than about 1.5 % of defects, less than about 1 % of defects, less than about 0.5 % of defects, less than about 0.1 % of defects less than about 005 %
of defects, or less than about 0.01 % of defects of the total surface.
[44] As used herein, the term "substantially," in, for example, the context "substantially identical" or "substantially similar" refers to a method or a system, or a component that is at least about 90%, at least about 91%, at least about 92%, at least about 93%, at least about 94%, at least about 95%, at least about 96%, at least about 97%, at least about 98%, at least about 99%, or about 100% by similar to the method, system, or the component it is compared to.
[45] As used herein, the terms a glass transition temperature or Tg can be used interchangeably and is defined as the inflection point of a differential scanning calorimetry (DSC) curve during the second heating, where the cooling and heating of the sample occurs at a rate of 10 C/min and is plotted as Heat Flow in mW vs.
Temperature in C.
[461 The term "liquidus viscosity," as used herein, refers to the shear viscosity of the glass composition at its liquidus temperature.
[47] The term "liquidus temperature," as used herein, refers to the highest temperature at which devitrification occurs in the glass composition.
[481 The term "CTE," as used herein, refers to the coefficient of thermal expansion of the glass composition averaged over a temperature range from about 25 C to about 300 C.
[491 As used herein, the term "ion-exchanged" refers to glass-ceramics that are chemically strengthened by ion exchange processes in which the glass-ceramic compositions are treated with a heated salt bath, spray, or paste containing ions having a different ionic radius than ions that are present in the glass-ceramic surface and/or bulk. The ions in the bath (or spray or paste) replace those ions in the glass-ceramic, which can be smaller in radius (or vice versa depending on the temperature conditions). Glass-ceramics that are subjected to such ion-exchange treatment(s) are referred to herein as "ion-exchanged glass-ceramic compositions (or articles)." It is further understood that the ion exchange process, as described herein, is not limited to salt baths, sprays, or pastes, and any other process that can ensure ion exchange within the glass-ceramics can also be included, for example, and without limitation, vapor-assisted, plasma-assisted, or sol-gel processes. Also, in some exemplary and unlimiting aspects, when a heated salt bath is used in the ion-exchange process, for example, such processes can be further accelerated by applying an electrical field to the bath.
[50] While aspects of the present invention can be described and claimed in a particular statutory class, such as the system statutory class, this is for convenience only and one of ordinary skill in the art will understand that each aspect of the present invention can be described and claimed in any statutory class. Unless otherwise expressly stated, it is in no way intended that any method or aspect set forth herein be construed as requiring that its steps be performed in a specific order.
Accordingly, where a method claim does not specifically state in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred in any respect. This holds for any possible non-express basis for interpretation, including matters of logic with respect to arrangement of steps or operational flow, plain meaning derived from grammatical organization or punctuation, or the number or type of aspects described in the specification.
[51] The present invention may be understood more readily by reference to the following detailed description of various aspects of the invention and the examples included therein and to the Figures and their previous and following description.
[52] The present invention may be understood more readily by reference to the following detailed description of various aspects of the invention and the examples included therein and to the Figures and their previous and following description.
COMPOSITIONS
[53] In some aspects described herein is a glass-ceramic composition comprising: a) from about 2 mol% to about 20 mol% of Al2O3; b) from about 2 mol%
to about 45 mo10/0 of Li2O, and c) from about 48 mol% to about 80 mol% of SiO2;
having a p-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase. In yet further aspects, disclosed is a glass-ceramic composition comprising: a) from about 3 mol% to about 12 mol% of Al2O3; b) from about 13 mol%
to about 45 mol% of U20; and c) from about 48 mole/0 to about 75 mol% of SiO2;
having a p-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase.
(541 It is understood that SO2 represents the largest component of the disclosed glass compositions. SiO2 is one of the most commonly studied glass-forming oxides.
Without wishing to be bound by any theory, it is understood that the high percent of S102 can be responsible for the high mechanical strength of the compositions, as SiO2 can stabilize the network structure of glass and glass-ceramics. In a certain aspect, where the amount of S102 is not high enough, 13-spodumene (U20.A1203-4Si02) and 13-spodumene solid solution ( U20.A1203.nSi02, can be preferably formed instead of petalite (U20.A1203-8Si02) crystals. Yet, in aspects where the amount of SiO2 is too high, the crystalline to amorphous ratio can be relatively low, resulting in a high melting temperature of the glass.
[55] In aspects disclosed herein, SiO2 can be present in any amount from about 48 to about 80 mol%, including exemplary values of about 50 mol%, about 51 mol%, about 52 mol%, about 53 mol%, about 54 mol%, about 55 mol%, about 56 mol%, about 57 mol%, about 58 mol%, about 59 mol%, about 60 mol%, about 61 mol%, about 62 mol%. about 63 mol%, about 64 mol%, about 65 mol%, about 66 mol%, about 67 mol%. about 68 mol%, about 69 mol%, about 70 mol%, about 71 mol%, about 72 mol%, about 73 mol%, about 74 mol%, about 75 mol%, about 76 mol%, about 77 mol%, about 78 mol%, and about 79 mol%. It is understood that SiO2 can be present in any amount having value between any two foregoing value, for example from about 45 mol% to about 75 mol%, or from about 55 mol% to about 80 mol%, or from about 65 mol% to about 80 mol%, or from about 65 mol% to about mol%.
(56] In still further aspects, it is understood that A1203 can also be a stabilizing component of the glass network structure. The presence of A1203 can also improve the mechanical properties of the glass (or glass-ceramic) compositions. In certain aspects, where the amount of A1203 is too high, the fraction of the petalite phase decreases according to the phase diagram. However, when the amount of A1203 is too low, the lithium silicate phase can be formed instead of the p-spodumene solid solution. In aspects disclosed herein, A1203 can be present in any amount from about 2 mol% to about 20 mol%, including exemplary values of about 3 mol%, about 4 mol%, about 5 mol%, about 6 mol%, about 7 mol%, about 8 mol%, about 9 mol%, about 10 mol%, about 11 mol%, about 12 mol%, about 13 mol%, about 14 mol%, about 15 mol%, about 16 mol%, about 17 mol%, about 18 mol%, and about 19 mol%. It is understood that A1203 can be present in any amount having a value between any two foregoing values, for example, from about 3 mol% to about 12 mol%, or from about 5 mol% to about 15 mol%, or from about 6 mol% to about 14 mol%.
[57] In glass and glass-ceramics, Li2O can be added to form both petalite and p-spodumene solid solution crystals. Without wishing to be bound by any theory, it is assumed that a high percent of Li2O increases the ion-exchange potential of glass ceramics, as Li atoms are relatively small compared with Na and K that can be used for ion-exchange. However, if the amount of L120 is too high, the composition can become very fluid, affecting the production cost. In aspects disclosed herein, Li2O
can be present in any amount from about 2 mol% to about 45 mol%, including exemplary values of about 3 mol%, about 4 mol%, about 5 mol%, about 6 mol%, about 7 mol%, about 8 mol%, about 9 mol%, about 10 mol%, about 11 mol%, about 12 mol%, about 13 mol%, about 14 mol%, about 15 mol%, about 16 mol%, about 17 mol%, about 18 mol%, about 19 mol%, about 20 mol%, about 21 mol%, about 22 mol%, about 23 mol%, about 24 mol%, about 25 mol%, about 26 mol%, about 27 mol%, about 28 mol%, about 29 mol%, about 30 mol%, about 31 mol%, about 32 mark, about 33 mol%, about 34 mol%, about 35 mol%, about 36 mol%, about 37 mol%, about 38 mol%, about 39 mol%, about 40 mol%, about 41 mol%, about 42 mol%, about 43 mol%, and about 44 mol%. It is understood that Li2O can be present in any amount having a value between any two foregoing values, for example, from about 13 mol% to about 45 mol%, or from about 5 mol% to about 15 mol%, or from about 8 mol% to about 12 mol%.
[58] In yet further aspects, when A1203 is present from about 5 mol% to about 7.5 mol 0/0, including exemplary values of about 5.1 mol%, about 5.2 mol%, about 5.3 mol%, about 5.4 mol%, about 5.5 mol%, about 5.6 mol%, about 5.7 mol%, about 5.8 mol%, about 5.9 mol%, about 6.0 mol%, about 6.1 mol%, about 6.2 mol%, about 6.3 mol%, about 6.4 mol%, about 6.5 mol%, about 6.6 mol%, about 6.7 mol%, about 6.8 M01%, about 6.9 mol%, about 6.9 mol%, about 7.0 mol%, about 7.1 mol%, about 7.2 mol%, about 7.3 mol%, and about 7.4 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the fi-spodumene phase and from about 20 to about 80% of the petalite phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
(59] In such exemplary aspects, the major crystalline phase can comprise from about 20 to about 80% of the13-spodumene phase, including exemplary values of about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, and about 75% of the 13-spodumene phase. In such exemplary aspects, the major phase can further comprise from about 20 to about 80% of thep-spodumene phase, including exemplary values of about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, and about 75% of the petalite phase. While in still further aspects, the minor crystalline phase can comprise up to about 10% of the lithium silicate phase, including exemplary values of about 0.01%, about 0.05%, about 0.1%, about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 9.5, and about 9.99%.
(60] In yet further exemplary aspects, when A1203 is present from about 5 mol%
to about 7.5 mol %, L120 can be present from about 20 mol% to about 25 mol%, including exemplary values of about 21 mol%, about 21.5 mol%, about 22 mol%, about 22.5 mol%, about 23 mol%, about 23.5 mol%, about 24 mol%, and about 24.5 mol%.
(61] In still further aspects, when Al2O3 is present from about 7 mol% to about 12 mol%, including exemplary values of about 7.1 mol%, about 7.2 mol%, about 7.3 mol%, about 7.4 mol%, about 7.5 mol%, about 7.6 mol%, about 7.7 mol%, about 7.8 mol%, about 7.9 mol%, about 8.0 mol%, about 8.1 mol%, about 8.2 mol%, about 8.3 mol%, about 8.4 mol%, about 8.5 mol%, about 8.6 mol%, about 8.7 mol%, about 8.8 mol%, about 8.9 mol%, about 9.0 mol%, about 9.1 mol%, about 9.2 mol%, about 9.3 mol%, and about 9.4 mol%, about 9.5 mol%, about 9.6 mol%, about 9.7 mol%, about 9.8 mol%, about 9.9 mol%, about 10.0 mol%, about 10.1 mol%, about 10.2 mol%, about 10.3 mol%, about 10.4 mol%, about 10.5 mol%, about 10.6 mol%, about 10.7 mol%, about 10.8 mol%, about 10.9 mol%, about 11.00 mol%, about 11.1 mol%, about 11.2 mol%, about 11.3 mol%, about 11.4 mol%, about 11.5 mol%, about 11.6 mol%, about 11.7 mol%, about 11.8 mol%, and about 11.9 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of thef3-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase. In such aspects, the major crystalline phase can comprise from about 60% to about 90% of the p-spodumene phase, including exemplary values of about 65%, about 70%, about 75%, about 80%, and about 85% of the p-spodumene phase. While in other aspects, the minor crystalline phase comprising up to about 10% of the lithium silicate phase, including exemplary values of greater than 0%, about 0.01%, about 0.05%, about 0.1%, about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 9.5%,about 9.9%, and about 9.99%.
[62] In yet further exemplary and unlimiting aspects, when the lithium silicate crystalline phase is present, such a phase can comprise a lithium metasilicate crystalline phase.
[63] In yet further aspects, a molar ratio of p-spodumene solid solution Li20:
A1203: Si02 can be in the range between about 1:1:4 and 1:1:8, including exemplary values of about 1:1:5, about 1:1:6, and about 1:1:7.
[64] In some exemplary aspects, the glass-ceramic compositions as disclosed herein can further comprise a) from 0 mol% to about 8 mol% of B203, b) from 0 mol% to about 8 mol% of Zr02, c) from 0 mol% to about 5 mol% of P205, and d) from 0 mol% to about 5 mol% of Na20. While, in other aspects, the glass-ceramic compositions as disclosed herein can further comprise a) from 0 mol% to about mol% of 8203, b) from 0 mol% to about 3 mol% of Zr02, c) from 0 mol% to about mol% of P205, and d) from 0 mol% to about 3 mol% of Na20.
[65] In such exemplary aspects, the B203 can be present in any amount from mol% to about 8 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about 4 mol%, about 5 mol%, about 6 mol%, and about 7 mol%. It is understood that 8203 can be present in any amount having a value between any two foregoing values, for example, from about 0.1 mol% to about 5 mol%, from about 0.1 mol% to about 3 mol%, or from about 0.1 mol% to about 2 mol%. It is understood that in some aspects, B203 can decrease the viscosity of the composition at the crystal-growth temperature and provide a three-coordinated network when boron is not charge-balanced by alkali oxides. Without wishing to be bound by any theory, it is assumed that such an exemplary structure can decrease the activation barrier for the movement of atoms from liquid to crystals, and thus lower the crystal-growth temperature and increase the crystalline to amorphous ratio. In still further aspects, B203 can increase chemical durability and glass-forming ability of the composition.
(661 In further aspects, the Zr02 can be present in any amount from 0 mol% to about 8 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about 4 mol%, about 5 mol%, about 6 mol%, and about 7 mol%. It is understood that Zr02 can be present in any amount having a value between any two foregoing values, for example, from 0 mol% to about 3 mol%, or from about 0.1 mol% to about 6 mol%, or from about 2 mol% to about 6 mol%. Again, without wishing to be bound by any theory, it is assumed that Zr02 can increase the transparency of LAS glass-ceramics. Without wishing by any theory, it is hypothesized that due to the large Zr atom, the activation barrier can be increased, leading to the decrease of the frequency of successful jump of atoms from liquid to crystals. A high concentration of Zr02 is hypothesized to decrease the crystal-growth temperature. However, in yet other aspects, the presence of a larger amount of Zr02 can increase the melting temperature of the glass.
(67] In further aspects, the P205 can be present in any amount from 0 mol% to about 5 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about and 4 mol%. It is understood that P205 can be present in any amount having a value between any two foregoing values, for example, from 0 mol% to about 3 mol%, or from about 0.1 mol% to about 5 mol%, or from about 1 mol% to about 5 mol%. In still further aspects, P205 can be a nucleation agent to produce bulk nucleation.
Without wishing to be bound by any theory, it is hypothesized that if the concentration of P205 is low, crystals can grow on the surface instead of in bulk. In such aspects, it is also assumed that the crystal growth rate is low. Without wishing to be bound by theory, it is further hypothesized that if the concentration of P205 is high, transparency can be affected, as the crystal growth rate can be fast and hard to control [68] In further aspects, the Na2O can be present in any amount from 0 mol%
to about 5 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about and 4 mol%. It is understood that Na2O can be present in any amount having a value between any two foregoing values, for example, from 0 mo10/0 to about 3 mol%, or from about 0.1 mol% to about 2 mol%, or from about 1 mol% to about 5 mol%.
Without wishing to be bound by any theory, it is hypothesized that Na2O can decrease the viscosity of glass and increase the glass-forming ability. Yet, in other aspects, high amounts of Na2O can decrease the crystalline to amorphous ratio and thus affect the toughness of glass-ceramics.
[69] In still further aspects, disclosed herein are glass-ceramic composition comprising: a) Al2O3 present from about 2 mol% to about 20 mol%, b) SiO2 present from about 48 mol% to about 80 mol%, c) R'20 present from greater than 0 mol%
to about 45 mol%; and wherein R'20 comprises Li2O, Na2O, K2O, Ag2O, Cu2O, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase. While in other aspects, disclosed herein are glass-ceramic composition comprising: a) Al2O3 present from about 3 mol% to about 12 mol%, b) SiO2 present from about 48 mol%
to about 75 mol%, c) R'20 present from greater than 0 mol% to about 45 mark;
and wherein R'20 comprises Li2O, Na2O, K20, Ag2O, Cu2O, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase. In certain aspects, such glass-ceramic compositions can be defined as ion-exchanged glass-ceramic compositions.
[70] In yet further aspects, when R'20 comprises Li2O, the composition can comprise a minor crystalline phase comprising a lithium silicate phase.
[71] In still further aspects, in such ion-exchanged compositions, SiO2 can be present in any amount from about 48 to about 80 mol%, including exemplary values of about 50 mol%, about 51 mol%, about 52 mol%, about 53 mol%, about 54 mol%, about 55 mol%, about 56 mol%, about 57 mol%, about 58 mol%, about 59 mol%, about 60 mol%, about 61 mol%, about 62 mol%, about 63 mol%, about 64 mol%, about 65 mol%. about 66 mol%, about 67 mol%, about 68 mol%, about 69 mol%, about 70 mol%, about 71 mol%, about 72 mol%, about 73 mol%, about 74 mol%, about 75 mol%, about 76 mol%, about 77 mol%, about 78 mol%, and about 79 mol%. It is understood that SiO2 can be present in any amount having value between any two foregoing value, for example from about 45 mark to about 75 mol%, or from about 55 mol% to about 80 mol%, or from about 65 mol% to about 80 mol%, or from about 65 mark to about 75 mol%.
[721 In yet other aspects, in such ion-exchanged compositions A1203 can be present in any amount from about 2 mol% to about 20 mol%, including exemplary values of about 3 mol%, about 4 mol%, about 5 mol%, about 6 mol%, about 7 mol%, about 8 mol%, about 9 mol%, about 10 mor/o, about 11 mol%, about 12 mol%, about 13 mol%, about 14 mol%, about 15 mol%. about 16 mol%, about 17 mol%, about 18 mol%, and about 19 mol%. It is understood that A1203 can be present in any amount having a value between any two foregoing values, for example, from about 3 mol%
to about 12 mol%, or from about 5 mol% to about 15 mol%, or from about 6 mol%
to about 14 mol%.
(731 In still other aspects, in such ion-exchanged compositions, R*20 can be present in any amount from 0 mol% to about 45 mol%, including exemplary values of about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about 4 mol%. about 5 mol%. about 6 mol%, about 7 mol%, about 8 mol%, about 9 mol%, about 10 mol%. about 11 mol%, about 12 mol%, about 13 mol%, about 14 mol%, about 15 mol%, about 16 mol%, about 17 mol%, about 18 mol%, about 19 mol%, about 20 mol%, about 21 mol%, about 22 mol%, about 23 mol%, about 24 mol%, about 25 mol%, about 26 mol%, about 27 mol%, about 28 mol%, about 29 mol%, about 30 mol%, about 31 mol%, about 32 mol%, about 33 mol%, about 34 mol%, about 35 mol%. about 36 mol%, about 37 mol%, about 38 mol%, about 39 mol%, about 40 mol%, about 41 mol%, about 42 mol%, about 43 mol%, and about 44 mol%. It is understood that R'20 can be present in any amount having value between any two foregoing value, for example from about 13 mol% to about 45 mol%, or from about 5 mol% to about 15 mol%, or from about 8 mol% to about 12 mol%.
[74] Similarly to the disclosed above compositions, wherein A1203 is present from about 5 mol% to about 7.5 mol %, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase and from about 20 to about 80% of the petalite phase. While in other aspects, when A1203 is present from about 5 mol% to about 7.5 mol % and L120 is present from mol% to about 25 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the ii-spodumene phase and from about 20 to about 80% of the petalite phase, and a minor phase comprises up to 10 mol% of the lithium silicate phase. In yet still, further aspects, when A1203 is present from about 7 mol% to about 12 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the 13-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase, if R'20 comprises Li.20.
[75] In still further aspects, the amount of R'20 can be adjusted to provide glass compositions exhibiting desired melting temperature and/or liquidus temperatures.
Without being bound by theory, the addition of alkali oxides, for example, can increase the coefficient of thermal expansion (GTE) and/or lower the chemical durability of the glasses and/or glass-ceramics that include such precursor glass compositions. The amount of excess alkali in a glass composition can also determine the ceramming or heat treatment temperature used to form the glass-ceramics.
[761 In still further aspects, such ion-exchanged glass-ceramic compositions can further comprise: a) from 0 mol% to about 8 mol% of 8203, b) from 0 mol% to about 8 mol% of Zr02, c) from 0 mol% to about 5 mol% of P205, and d) from 0 mol% to about 5 mol% of Na20. While, in other aspects, the glass-ceramic compositions as disclosed herein can further comprise a) from 0 mol% to about 5 mol% of 8203, b) from 0 mol% to about 3 mol% of Zr02, c) from 0 mol% to about 3 mol% of P205, and d) from 0 mol% to about 3 mol% of Na20.
(77] In such exemplary aspects, the 8203 can be present in any amount from 0 mo10/0 to about 8 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about 4 mol%, about 5 mol%, about 6 mol%, and about 7 mol%. It is understood that 8203 can be present in any amount having a value between any two foregoing values, for example, from about 0.1 mol% to about 5 mol%, from about 0.1 mol% to about 3 mol%, or from about 0.1 mol% to about 2 mol%.
[78] In further aspects, the Zr02 can be present in any amount from 0 mol% to about 8 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mar/0, about 1 mol%, about 2 mol%, about 3 mol%, about 4 ince/0, about 5 mol%, about 6 mol%, and about 7 mol%. It is understood that ZrO2 can be present in any amount having a value between any two foregoing values, for example, from 0 mol% to about 3 morY0, or from about 0.1 mol% to about 6 mol%, or from about 2 mol% to about 6 mol%.
[791 In further aspects, the P205 can be present in any amount from 0 mol% to about 5 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about and 4 mol%. It is understood that P205 can be present in any amount having a value between any two foregoing values, for example, from 0 mol% to about 3 mol%, or from about 0.1 mol% to about 5 mol%, or from about 1 mol% to about 5 mol%.
DM In further aspects, the Na20 can be present in any amount from 0 mol% to about 5 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about and 4 mol%. It is understood that Na2O can be present in any amount having a value between any two foregoing values, for example, from 0 mol% to about 3 mol%, or from about 0.1 mol% to about 2 mol%, or from about 1 mol% to about 5 mol%.
(811 In yet further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit density from about 2.00 9/cm3 to about 2.6 g/cm3, including exemplary value of about 2.01 g/cm3, about 2.02 g/cm3, about 2.03 g/cm3, about 2.04 g/cm3, about 2.05 g/cm3, about 2.06 g/cm3, about 2.07 g/cm3, about 2.08 gicm3, about 2.09 g/cm3, about 2.1 9/cm3, about 2.11 9/cm3, about 2.12 g/cm3, about 2.13 g/cm3, about 2.14 g/cm3, about 2.15 g/cm3, about 2.16 g/crn3, about 2.17 g/cm3, about 2.18 9/cm3, about 2.19 g/cm3, about 2.20 g/cm3, about 2.21 g/cm3, about 2.22 g/cm3, about 2.23 g/cm3, and about 2.24 g/cm3, about 2.25 g/cm3, about 2.26 g/cm3, about 2.27 g/cm3, about 2.28 g/cm3, about 2.29 g/cm3, about 2.30 g/cm3, about 2.31 g/cm3, about 2.32 g/cm3, about 2.33 g/cm3, and about 2.34 g/cm3, about 2.35 g/cm3, about 2.36 g/cm3, about 2.37 g/cm3, about 2.38 9/cm3, about 2.39 g/cm3, about 2.4 g/cm3, about 2.41 g/cm3, about 2.42 9/cm3, about 2.43 g1cm3, about 2.44 g/cm3, about 2.45 g/cm3, about 2.46 g/cm3, about 2.47 g/cm3, about 2.48 g/cm3, about 2.49 g1cm3, about 2.5 g/cm3, about 2.51 g/cm3, about 2.52 9/cm3, about 2.53 g/cm3, about 2.54 g/cm3, about 2.55 g/cm3, about 2.56 g/cm3, about 2.57 g/cm3, about 2.58 9/cm3, and about 2.59 g/cm3.
(82] In still further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit an average transmittance greater than about 80% over a wavelength range from about 390 nm to about 700 nm as measured for a sample prepared from the composition and having a thickness of about 2.00 mm. In such exemplary aspects, the average transmittance can be greater than about 81%, about 82%, about 83%, about 84%, about 85%, about 86 %, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 99.5%, and about 99.99%. In still further aspects, the average transmittance is measured over a wavelength range from about 390 nm to about 700 nm, including exemplary values of about 400 nm, about 450 nm, about 500 nm, about 550 nm, about 600 nm, and about 650 nm. It is understood that in such exemplary aspects, the glass-ceramic composition is substantially transparent. In yet other aspects, the glass-ceramic composition is transparent. In still further exemplary aspects, the glass-ceramic composition comprises a plurality of crystal grains, wherein the median size of a crystal grain is from about 20 to about 80 nm, including exemplary values of about 25 nm, about nm, about 35 nm, about 40 nm, about 45 nm, about 50 nm, about 55 nm, about 60 nm, about 65 nm, about 70 nm, and about 75 nm.
(83] In yet other aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit an average transmittance between 20% and 80% over a wavelength range from about 390 nm to about 700 nm as measured for a sample prepared from the composition and having a thickness of about 2.00 mm. In such exemplary aspects, the average transmittance is about 20%, about 25%, about 30%, about 35, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75% and about 80%. In still further aspects, the average transmittance is measured over a wavelength range from about 390 nm to about 700 nm, including exemplary values of about 400 nm, about 450 nm, about 500 nm, about 550 nm, about 600 nm, and about 650 nm. It is understood that in such exemplary aspects, the glass-ceramic composition is substantially translucent. In yet other aspects, the glass-ceramic composition is translucent. In still further exemplary aspects, the glass-ceramic composition comprises a plurality of crystal grains, wherein the median size of a crystal grain is from about 80 to about 500 nm, including exemplary values of about 100 nm. about 120 nm, about 150 nm, about 170 nm, about 200 nm, about 220 nm, about 250 nm, about 270 nm, about 300 nm, about 320 nm, about 350 nm, about 370 nm, about 400 nm, about 420 nm, about 450 nm, and about 470 nm.
[84] In yet other aspects, any of the disclosed herein glass-ceramic compositions(both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit an average transmittance lower than 20% over a wavelength range from about 390 nm to about 700 nm as measured for a sample prepared from the composition and having a thickness of about 2.00 mm. In such exemplary aspects, the average transmittance is about 20%, about 19%, about 18%, about 17, about 16%, about 15%, about 14%, about 13%, about 12%, about 11%, about 10%, about 9%, about 8%, about 7, about 6%, about 5%, about 4%, about 3%, about 2%, and about 1%. In still further aspects, the average transmittance is measured over a wavelength range from about 390 nm to about 700 nm, including exemplary values of about 400 nm, about 450 nm, about 500 nm, about 550 nm, about 600 nm, and about 650 nm. It is understood that in such exemplary aspects, the glass-ceramic composition is substantially opaque. In yet other aspects, the glass-ceramic composition is opaque. In still further exemplary aspects, the glass-ceramic composition comprises a plurality of crystal grains, wherein the median size of a crystal grain is greater than about 500 nm, greater than about 550 rim, greater than about 600 nm, greater than about 650 nm, greater than about 700 nm, greater than about 750 nm, greater than about 800 nm, greater than about 850 nm, greater than about 900 rim, greater than about 950 rim, or greater than about 1,000 nm.
[851 In still further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit Vickers hardness equal to or greater than about 6.0 GPa, or greater than about 7 GPa, or greater than about 8 GPa, or greater than about 9 GPa, or greater than about 10 GPa.
[86] In still further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit Vickers hardness of at least about 5% greater than Vickers hardness of a standard soda lime silicate glass, or at least about 7% greater, at least about 10% greater, at least about 15% greater, at least about 20% greater, at least about 25 % greater, or at least about 50% greater than Vickers hardness of a standard soda lime silicate glass.
[871 In still further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit a crack-resistance greater than about 0.2 kgf, about 0.4 kgf. about 0.6 kgf, about 0.8 kgf, or greater than about 1 kgf, or greater than about 1.5 kgf, greater than about 2 kgf, greater than about 5 kgf, or greater than about 10 kgf. In still further exemplary aspects, the glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) disclosed herein can exhibit a crack-resistance that at least 4 times higher, at least 5 times higher, at least 6 times higher, at least 7 times higher, at least 8 times higher, at least 9 times higher, or at least 10 times higher than a crack-resistance of a standard soda lime silicate glass.
[88] In still further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit a thermal expansion coefficient from about 40x107 to about 90x107 Pc, including exemplary values of about 41x1 07/ C, about 42x107 / C, about 43x107 1 C, about 44x1 / C, about 45x10-7 1 C, about 46x107 1 C, about 47x107 / C, about 48x1 1 C, about 49x10-7 PC, about 50x10-7/"C, about 51x107 1 C, about 52x10-71 C, about 53x10-7/ C, about 54x10-7 PC, about 55x107 / C, about 56x1 , about 57x107 / C, about 58x10-7 1 C, about 59x107 1 C, about 60x107 / C, about 61x107 / C, about 62x10-7/ C, about 63x10-7 PC, about 64x107 / C, about 65x104 1 C, about 66x104 1 C, about 67x10-7 / C, about 68x107 1 C, about 69x10-/ C, about 70x107/ C, about 71x10-7/0C, about 72x1071 C, about 73x107 / C, about 74x10-7/ C, about 75x10-7/ C, about 76x10-7/ C, about 77x10-7/ C, about 78x10-1 C, about 79x1071 C, about 80x107 / C, about 81x10.7 1 C, about 82x107 / C, about 83x104 1 C, about 84x1041 C, about 85x10.7 1 C, about 86x104 1 C, about 87x104 1 C, about 88x10.7 1 C, and about 89x107 PC. It is understood that in such aspects, C is averaged over a temperature range from about 25 C to about 300 C. It is understood that the glass-ceramic compositions can comprise any thermal expansion value between any two foregoing values.
[891 In yet further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) comprises a glass transition temperature (Tg) from about 450 C
to about 600 CC, including exemplary values of about 460 C, about 470 C, about C, about 490 C, about 500 C, about 510 C, about 520 C, about 530 C, about 540 C, about 550 C, about 560 C, about 570 C, about 580 C, and about 590 C.
(90] In still further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can comprise one or more fining agents. In certain aspects, the compositions can comprise from greater than 0 mol% to about 1 mol% of a fining agent, including exemplary value of about 0.1 mole%, about 0.2 mol%, about 0.3 mol%, about 0.4 mol%, about 0.5 mol%, about 0.6 mol%, about 0.7 mol%, about 0.8 mol%, and about 0.9 mol%. It is understood that the fining agent can be present in any amount having a value between any two foregoing values.
[911 In still further aspects, the fining agent can comprise any fining agent known in the art. In certain aspects, the fining agent can comprise a salt, a metallic oxide, or any combination thereof. In certain aspects, where the fining agent comprises a salt, such salt can comprise sulfate, chloride, iodide, bromide, or a combination thereof.
Yet in further aspects, where the fining agent comprises a metal oxide, the metal oxide can comprise Ce02, Sn02, Fe2O3, A5203, Sb203, Mn02, or a combination thereof. However, in yet other aspects, the glass composition does not comprise any heavy metals. In such aspects, the glass composition is substantially free of heavy metals.
[92] In certain aspects, the addition of the fining agent can reduce bubble formation in glass melts to reduce the population of bubbles in the glass-ceramics.
[93] It is understood that in some aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can also comprise other components. For example, and without limitations, the disclosed compositions can comprise one or more coloring components. In such aspects, the one or more of coloring components are selected from transition metal oxides and/or rare earth metal oxide. For example, and without limitations, the one or more of coloring components can comprise V205, Cr203, Ti02, Mn02, MO, ZnO, CuO, C0304, and combinations thereof. In aspects where the coloring components are present, these components are present in a total amount equal to or less than about 1 mol%, less than about 0.9 mol%, less than about 0.8 mol%, less than about 0.7 mol%, less than about 0.6 mol%, less than about 0.5 mol%, less than about 0.4 mork, less than about 0.3 mol%, less than about 0.2 mol%, less than about 0.1 mol%. It is understood that the coloring components can be present in any amount having a value between any two foregoing values.
[94] In still further aspects, to avoid a possible undesired coloring effect on the disclosed herein glass-ceramic compositions, some trace amounts of decolorizing agents can be added. In such aspects, the decolorizing agents can comprise one or more of sodium sulphate, selenium compounds, erbium oxide, cerium oxide, cobalt oxide, manganese oxide, and other polyvalent elements. In still further aspects, these decolorizing agents can reduce colorization through any mechanisms known in the art, including chemical and/or physical mechanisms. In yet still further aspects, these agents can be present in a total amount equal to or less than about 1 mol%, less than about 0.9 mol%, less than about 0.8 mol%, less than about 0.7 mol%, less than about 0.6 mol%, less than about 0.5 mol%, less than about 0.4 mol%, less than about 0.3 mol%, less than about 0.2 mor/o, less than about 0.1 mol%, less than about 0.05 mol%, or less than about 0.01 mol%. It is understood that the decolorizing agents can be present in any amount having a value between any two foregoing values.
[951 In yet further aspects, any of the disclosed herein glass-ceramic compositions can be ion-exchangeable.
(96] In still further aspects, such ion-exchanged glass-ceramic compositions can also be substantially transparent. While in other aspects, such ion-exchanged glass-ceramic compositions are substantially translucent. While in still further aspects, such ion-exchanged glass-ceramic compositions are substantially opaque.
[971 In still further aspects, these ion-exchanged glass-ceramic compositions can comprise a compressive stress layer. It is understood that such a layer is formed by an ion-exchange process.
[98] In still further aspects, when the glass-ceramic compositions comprise R'20, and when R'20 comprises Ag2O, and/or Cu20, and/or CuO, such compositions can also exhibit antimicrobial, antiviral, antibacterial, and/or antifungal properties.
(99] In still further aspects, the glass compositions described herein can be substantially transparent in a wavelength range from about 400 nm to about 800 nm.
In some exemplary and unlimiting aspects, the glass compositions exhibit percent transmittance greater than about 87%, greater than about 88%, greater than about 89%, greater than about 90%, greater than about 91%, greater than about 92%, greater than about 93%, greater than about 94%, greater than about 95%, greater than about 96%, greater than about 97%, greater than about 98%, greater than about 99%, over a wavelength range from about 400 am to about 800 am, including an exemplary value of about 430 am, about 450 am, about 470 nm, about 500 nm, about 530 nm, about 550 nm, about 570 nm, about 600 nm, about 630 nm, about 650 am. about 670 am, about 700 nm, about 730 nm, about 750 nm, and about 770 am.
ARTICLES
000] In certain aspects, disclosed herein are articles comprising any of the disclosed above compositions. For example and without limitations disclosed herein are articles comprising: a) from about 2 mol% to about 20 mol% of Al2O3, b) from about 2 mol% to about 45 mol% of Li2O; and from about 48 mol% to about 80 mol%
of SiO2; having a fi-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase. While in other aspects, disclosed herein are articles comprising: a) from about 3 mol% to about 12 mol% of Al2O3, b) from about 13 mol%
to about 45 mol% of 1..i20; and from about 48 mo10/0 to about 75 mol% of SiO2;
having a ii-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase.
[101] While in still further aspects, disclosed herein are articles comprising: a) from about 2 mol% to about 20 mol% of A1203, b) S102 present from about 48 mol%
to about 80 mol%; and R'20 present from greater than 0 mol% to about 45 mol%;
wherein R'20 comprises Li20, Na20, 1<20, Ag20, Cu20, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase. While in other aspects, disclosed herein are articles comprising: a) from about 3 mol% to about 12 mol% of A1203, b) Si02 present from about 48 mol% to about 75 mol%; and R'20 present from greater than 0 mol% to about 45 mol%; wherein R'20 comprises Li20, Na20, 1<20, Ag20, 0u20, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase.
[102] In certain aspects, also disclosed are glass-ceramic articles comprising compositions having the compressive stress layers. In such exemplary aspects, the compressive stress layer can extend from a surface of the article to a depth of the compressive stress layer, wherein the depth is from about 1 pm to about 100 pm, including exemplary values of about 2 pm, about 5 pm, about 10 pm, about 15 pm, about 20 pm, about 25 pm, about 30 pm, about 35 pm, about 40 pm, about 45 pm, about 50 pm, about 55 pm, about 60 pm, about 65 pm, about 70 pm, about 75 pm, about 80 pm, about 85 pm, about 90 pm, and about 95 pm. In yet further aspects, the depth of the compressive layer can be up to about 25 % of a thickness of the glass-ceramic article, including exemplary values of about 1%, about 5%, about
of defects, or less than about 0.01 % of defects of the total surface.
[44] As used herein, the term "substantially," in, for example, the context "substantially identical" or "substantially similar" refers to a method or a system, or a component that is at least about 90%, at least about 91%, at least about 92%, at least about 93%, at least about 94%, at least about 95%, at least about 96%, at least about 97%, at least about 98%, at least about 99%, or about 100% by similar to the method, system, or the component it is compared to.
[45] As used herein, the terms a glass transition temperature or Tg can be used interchangeably and is defined as the inflection point of a differential scanning calorimetry (DSC) curve during the second heating, where the cooling and heating of the sample occurs at a rate of 10 C/min and is plotted as Heat Flow in mW vs.
Temperature in C.
[461 The term "liquidus viscosity," as used herein, refers to the shear viscosity of the glass composition at its liquidus temperature.
[47] The term "liquidus temperature," as used herein, refers to the highest temperature at which devitrification occurs in the glass composition.
[481 The term "CTE," as used herein, refers to the coefficient of thermal expansion of the glass composition averaged over a temperature range from about 25 C to about 300 C.
[491 As used herein, the term "ion-exchanged" refers to glass-ceramics that are chemically strengthened by ion exchange processes in which the glass-ceramic compositions are treated with a heated salt bath, spray, or paste containing ions having a different ionic radius than ions that are present in the glass-ceramic surface and/or bulk. The ions in the bath (or spray or paste) replace those ions in the glass-ceramic, which can be smaller in radius (or vice versa depending on the temperature conditions). Glass-ceramics that are subjected to such ion-exchange treatment(s) are referred to herein as "ion-exchanged glass-ceramic compositions (or articles)." It is further understood that the ion exchange process, as described herein, is not limited to salt baths, sprays, or pastes, and any other process that can ensure ion exchange within the glass-ceramics can also be included, for example, and without limitation, vapor-assisted, plasma-assisted, or sol-gel processes. Also, in some exemplary and unlimiting aspects, when a heated salt bath is used in the ion-exchange process, for example, such processes can be further accelerated by applying an electrical field to the bath.
[50] While aspects of the present invention can be described and claimed in a particular statutory class, such as the system statutory class, this is for convenience only and one of ordinary skill in the art will understand that each aspect of the present invention can be described and claimed in any statutory class. Unless otherwise expressly stated, it is in no way intended that any method or aspect set forth herein be construed as requiring that its steps be performed in a specific order.
Accordingly, where a method claim does not specifically state in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred in any respect. This holds for any possible non-express basis for interpretation, including matters of logic with respect to arrangement of steps or operational flow, plain meaning derived from grammatical organization or punctuation, or the number or type of aspects described in the specification.
[51] The present invention may be understood more readily by reference to the following detailed description of various aspects of the invention and the examples included therein and to the Figures and their previous and following description.
[52] The present invention may be understood more readily by reference to the following detailed description of various aspects of the invention and the examples included therein and to the Figures and their previous and following description.
COMPOSITIONS
[53] In some aspects described herein is a glass-ceramic composition comprising: a) from about 2 mol% to about 20 mol% of Al2O3; b) from about 2 mol%
to about 45 mo10/0 of Li2O, and c) from about 48 mol% to about 80 mol% of SiO2;
having a p-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase. In yet further aspects, disclosed is a glass-ceramic composition comprising: a) from about 3 mol% to about 12 mol% of Al2O3; b) from about 13 mol%
to about 45 mol% of U20; and c) from about 48 mole/0 to about 75 mol% of SiO2;
having a p-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase.
(541 It is understood that SO2 represents the largest component of the disclosed glass compositions. SiO2 is one of the most commonly studied glass-forming oxides.
Without wishing to be bound by any theory, it is understood that the high percent of S102 can be responsible for the high mechanical strength of the compositions, as SiO2 can stabilize the network structure of glass and glass-ceramics. In a certain aspect, where the amount of S102 is not high enough, 13-spodumene (U20.A1203-4Si02) and 13-spodumene solid solution ( U20.A1203.nSi02, can be preferably formed instead of petalite (U20.A1203-8Si02) crystals. Yet, in aspects where the amount of SiO2 is too high, the crystalline to amorphous ratio can be relatively low, resulting in a high melting temperature of the glass.
[55] In aspects disclosed herein, SiO2 can be present in any amount from about 48 to about 80 mol%, including exemplary values of about 50 mol%, about 51 mol%, about 52 mol%, about 53 mol%, about 54 mol%, about 55 mol%, about 56 mol%, about 57 mol%, about 58 mol%, about 59 mol%, about 60 mol%, about 61 mol%, about 62 mol%. about 63 mol%, about 64 mol%, about 65 mol%, about 66 mol%, about 67 mol%. about 68 mol%, about 69 mol%, about 70 mol%, about 71 mol%, about 72 mol%, about 73 mol%, about 74 mol%, about 75 mol%, about 76 mol%, about 77 mol%, about 78 mol%, and about 79 mol%. It is understood that SiO2 can be present in any amount having value between any two foregoing value, for example from about 45 mol% to about 75 mol%, or from about 55 mol% to about 80 mol%, or from about 65 mol% to about 80 mol%, or from about 65 mol% to about mol%.
(56] In still further aspects, it is understood that A1203 can also be a stabilizing component of the glass network structure. The presence of A1203 can also improve the mechanical properties of the glass (or glass-ceramic) compositions. In certain aspects, where the amount of A1203 is too high, the fraction of the petalite phase decreases according to the phase diagram. However, when the amount of A1203 is too low, the lithium silicate phase can be formed instead of the p-spodumene solid solution. In aspects disclosed herein, A1203 can be present in any amount from about 2 mol% to about 20 mol%, including exemplary values of about 3 mol%, about 4 mol%, about 5 mol%, about 6 mol%, about 7 mol%, about 8 mol%, about 9 mol%, about 10 mol%, about 11 mol%, about 12 mol%, about 13 mol%, about 14 mol%, about 15 mol%, about 16 mol%, about 17 mol%, about 18 mol%, and about 19 mol%. It is understood that A1203 can be present in any amount having a value between any two foregoing values, for example, from about 3 mol% to about 12 mol%, or from about 5 mol% to about 15 mol%, or from about 6 mol% to about 14 mol%.
[57] In glass and glass-ceramics, Li2O can be added to form both petalite and p-spodumene solid solution crystals. Without wishing to be bound by any theory, it is assumed that a high percent of Li2O increases the ion-exchange potential of glass ceramics, as Li atoms are relatively small compared with Na and K that can be used for ion-exchange. However, if the amount of L120 is too high, the composition can become very fluid, affecting the production cost. In aspects disclosed herein, Li2O
can be present in any amount from about 2 mol% to about 45 mol%, including exemplary values of about 3 mol%, about 4 mol%, about 5 mol%, about 6 mol%, about 7 mol%, about 8 mol%, about 9 mol%, about 10 mol%, about 11 mol%, about 12 mol%, about 13 mol%, about 14 mol%, about 15 mol%, about 16 mol%, about 17 mol%, about 18 mol%, about 19 mol%, about 20 mol%, about 21 mol%, about 22 mol%, about 23 mol%, about 24 mol%, about 25 mol%, about 26 mol%, about 27 mol%, about 28 mol%, about 29 mol%, about 30 mol%, about 31 mol%, about 32 mark, about 33 mol%, about 34 mol%, about 35 mol%, about 36 mol%, about 37 mol%, about 38 mol%, about 39 mol%, about 40 mol%, about 41 mol%, about 42 mol%, about 43 mol%, and about 44 mol%. It is understood that Li2O can be present in any amount having a value between any two foregoing values, for example, from about 13 mol% to about 45 mol%, or from about 5 mol% to about 15 mol%, or from about 8 mol% to about 12 mol%.
[58] In yet further aspects, when A1203 is present from about 5 mol% to about 7.5 mol 0/0, including exemplary values of about 5.1 mol%, about 5.2 mol%, about 5.3 mol%, about 5.4 mol%, about 5.5 mol%, about 5.6 mol%, about 5.7 mol%, about 5.8 mol%, about 5.9 mol%, about 6.0 mol%, about 6.1 mol%, about 6.2 mol%, about 6.3 mol%, about 6.4 mol%, about 6.5 mol%, about 6.6 mol%, about 6.7 mol%, about 6.8 M01%, about 6.9 mol%, about 6.9 mol%, about 7.0 mol%, about 7.1 mol%, about 7.2 mol%, about 7.3 mol%, and about 7.4 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the fi-spodumene phase and from about 20 to about 80% of the petalite phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
(59] In such exemplary aspects, the major crystalline phase can comprise from about 20 to about 80% of the13-spodumene phase, including exemplary values of about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, and about 75% of the 13-spodumene phase. In such exemplary aspects, the major phase can further comprise from about 20 to about 80% of thep-spodumene phase, including exemplary values of about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, and about 75% of the petalite phase. While in still further aspects, the minor crystalline phase can comprise up to about 10% of the lithium silicate phase, including exemplary values of about 0.01%, about 0.05%, about 0.1%, about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 9.5, and about 9.99%.
(60] In yet further exemplary aspects, when A1203 is present from about 5 mol%
to about 7.5 mol %, L120 can be present from about 20 mol% to about 25 mol%, including exemplary values of about 21 mol%, about 21.5 mol%, about 22 mol%, about 22.5 mol%, about 23 mol%, about 23.5 mol%, about 24 mol%, and about 24.5 mol%.
(61] In still further aspects, when Al2O3 is present from about 7 mol% to about 12 mol%, including exemplary values of about 7.1 mol%, about 7.2 mol%, about 7.3 mol%, about 7.4 mol%, about 7.5 mol%, about 7.6 mol%, about 7.7 mol%, about 7.8 mol%, about 7.9 mol%, about 8.0 mol%, about 8.1 mol%, about 8.2 mol%, about 8.3 mol%, about 8.4 mol%, about 8.5 mol%, about 8.6 mol%, about 8.7 mol%, about 8.8 mol%, about 8.9 mol%, about 9.0 mol%, about 9.1 mol%, about 9.2 mol%, about 9.3 mol%, and about 9.4 mol%, about 9.5 mol%, about 9.6 mol%, about 9.7 mol%, about 9.8 mol%, about 9.9 mol%, about 10.0 mol%, about 10.1 mol%, about 10.2 mol%, about 10.3 mol%, about 10.4 mol%, about 10.5 mol%, about 10.6 mol%, about 10.7 mol%, about 10.8 mol%, about 10.9 mol%, about 11.00 mol%, about 11.1 mol%, about 11.2 mol%, about 11.3 mol%, about 11.4 mol%, about 11.5 mol%, about 11.6 mol%, about 11.7 mol%, about 11.8 mol%, and about 11.9 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of thef3-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase. In such aspects, the major crystalline phase can comprise from about 60% to about 90% of the p-spodumene phase, including exemplary values of about 65%, about 70%, about 75%, about 80%, and about 85% of the p-spodumene phase. While in other aspects, the minor crystalline phase comprising up to about 10% of the lithium silicate phase, including exemplary values of greater than 0%, about 0.01%, about 0.05%, about 0.1%, about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 9.5%,about 9.9%, and about 9.99%.
[62] In yet further exemplary and unlimiting aspects, when the lithium silicate crystalline phase is present, such a phase can comprise a lithium metasilicate crystalline phase.
[63] In yet further aspects, a molar ratio of p-spodumene solid solution Li20:
A1203: Si02 can be in the range between about 1:1:4 and 1:1:8, including exemplary values of about 1:1:5, about 1:1:6, and about 1:1:7.
[64] In some exemplary aspects, the glass-ceramic compositions as disclosed herein can further comprise a) from 0 mol% to about 8 mol% of B203, b) from 0 mol% to about 8 mol% of Zr02, c) from 0 mol% to about 5 mol% of P205, and d) from 0 mol% to about 5 mol% of Na20. While, in other aspects, the glass-ceramic compositions as disclosed herein can further comprise a) from 0 mol% to about mol% of 8203, b) from 0 mol% to about 3 mol% of Zr02, c) from 0 mol% to about mol% of P205, and d) from 0 mol% to about 3 mol% of Na20.
[65] In such exemplary aspects, the B203 can be present in any amount from mol% to about 8 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about 4 mol%, about 5 mol%, about 6 mol%, and about 7 mol%. It is understood that 8203 can be present in any amount having a value between any two foregoing values, for example, from about 0.1 mol% to about 5 mol%, from about 0.1 mol% to about 3 mol%, or from about 0.1 mol% to about 2 mol%. It is understood that in some aspects, B203 can decrease the viscosity of the composition at the crystal-growth temperature and provide a three-coordinated network when boron is not charge-balanced by alkali oxides. Without wishing to be bound by any theory, it is assumed that such an exemplary structure can decrease the activation barrier for the movement of atoms from liquid to crystals, and thus lower the crystal-growth temperature and increase the crystalline to amorphous ratio. In still further aspects, B203 can increase chemical durability and glass-forming ability of the composition.
(661 In further aspects, the Zr02 can be present in any amount from 0 mol% to about 8 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about 4 mol%, about 5 mol%, about 6 mol%, and about 7 mol%. It is understood that Zr02 can be present in any amount having a value between any two foregoing values, for example, from 0 mol% to about 3 mol%, or from about 0.1 mol% to about 6 mol%, or from about 2 mol% to about 6 mol%. Again, without wishing to be bound by any theory, it is assumed that Zr02 can increase the transparency of LAS glass-ceramics. Without wishing by any theory, it is hypothesized that due to the large Zr atom, the activation barrier can be increased, leading to the decrease of the frequency of successful jump of atoms from liquid to crystals. A high concentration of Zr02 is hypothesized to decrease the crystal-growth temperature. However, in yet other aspects, the presence of a larger amount of Zr02 can increase the melting temperature of the glass.
(67] In further aspects, the P205 can be present in any amount from 0 mol% to about 5 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about and 4 mol%. It is understood that P205 can be present in any amount having a value between any two foregoing values, for example, from 0 mol% to about 3 mol%, or from about 0.1 mol% to about 5 mol%, or from about 1 mol% to about 5 mol%. In still further aspects, P205 can be a nucleation agent to produce bulk nucleation.
Without wishing to be bound by any theory, it is hypothesized that if the concentration of P205 is low, crystals can grow on the surface instead of in bulk. In such aspects, it is also assumed that the crystal growth rate is low. Without wishing to be bound by theory, it is further hypothesized that if the concentration of P205 is high, transparency can be affected, as the crystal growth rate can be fast and hard to control [68] In further aspects, the Na2O can be present in any amount from 0 mol%
to about 5 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about and 4 mol%. It is understood that Na2O can be present in any amount having a value between any two foregoing values, for example, from 0 mo10/0 to about 3 mol%, or from about 0.1 mol% to about 2 mol%, or from about 1 mol% to about 5 mol%.
Without wishing to be bound by any theory, it is hypothesized that Na2O can decrease the viscosity of glass and increase the glass-forming ability. Yet, in other aspects, high amounts of Na2O can decrease the crystalline to amorphous ratio and thus affect the toughness of glass-ceramics.
[69] In still further aspects, disclosed herein are glass-ceramic composition comprising: a) Al2O3 present from about 2 mol% to about 20 mol%, b) SiO2 present from about 48 mol% to about 80 mol%, c) R'20 present from greater than 0 mol%
to about 45 mol%; and wherein R'20 comprises Li2O, Na2O, K2O, Ag2O, Cu2O, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase. While in other aspects, disclosed herein are glass-ceramic composition comprising: a) Al2O3 present from about 3 mol% to about 12 mol%, b) SiO2 present from about 48 mol%
to about 75 mol%, c) R'20 present from greater than 0 mol% to about 45 mark;
and wherein R'20 comprises Li2O, Na2O, K20, Ag2O, Cu2O, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase. In certain aspects, such glass-ceramic compositions can be defined as ion-exchanged glass-ceramic compositions.
[70] In yet further aspects, when R'20 comprises Li2O, the composition can comprise a minor crystalline phase comprising a lithium silicate phase.
[71] In still further aspects, in such ion-exchanged compositions, SiO2 can be present in any amount from about 48 to about 80 mol%, including exemplary values of about 50 mol%, about 51 mol%, about 52 mol%, about 53 mol%, about 54 mol%, about 55 mol%, about 56 mol%, about 57 mol%, about 58 mol%, about 59 mol%, about 60 mol%, about 61 mol%, about 62 mol%, about 63 mol%, about 64 mol%, about 65 mol%. about 66 mol%, about 67 mol%, about 68 mol%, about 69 mol%, about 70 mol%, about 71 mol%, about 72 mol%, about 73 mol%, about 74 mol%, about 75 mol%, about 76 mol%, about 77 mol%, about 78 mol%, and about 79 mol%. It is understood that SiO2 can be present in any amount having value between any two foregoing value, for example from about 45 mark to about 75 mol%, or from about 55 mol% to about 80 mol%, or from about 65 mol% to about 80 mol%, or from about 65 mark to about 75 mol%.
[721 In yet other aspects, in such ion-exchanged compositions A1203 can be present in any amount from about 2 mol% to about 20 mol%, including exemplary values of about 3 mol%, about 4 mol%, about 5 mol%, about 6 mol%, about 7 mol%, about 8 mol%, about 9 mol%, about 10 mor/o, about 11 mol%, about 12 mol%, about 13 mol%, about 14 mol%, about 15 mol%. about 16 mol%, about 17 mol%, about 18 mol%, and about 19 mol%. It is understood that A1203 can be present in any amount having a value between any two foregoing values, for example, from about 3 mol%
to about 12 mol%, or from about 5 mol% to about 15 mol%, or from about 6 mol%
to about 14 mol%.
(731 In still other aspects, in such ion-exchanged compositions, R*20 can be present in any amount from 0 mol% to about 45 mol%, including exemplary values of about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about 4 mol%. about 5 mol%. about 6 mol%, about 7 mol%, about 8 mol%, about 9 mol%, about 10 mol%. about 11 mol%, about 12 mol%, about 13 mol%, about 14 mol%, about 15 mol%, about 16 mol%, about 17 mol%, about 18 mol%, about 19 mol%, about 20 mol%, about 21 mol%, about 22 mol%, about 23 mol%, about 24 mol%, about 25 mol%, about 26 mol%, about 27 mol%, about 28 mol%, about 29 mol%, about 30 mol%, about 31 mol%, about 32 mol%, about 33 mol%, about 34 mol%, about 35 mol%. about 36 mol%, about 37 mol%, about 38 mol%, about 39 mol%, about 40 mol%, about 41 mol%, about 42 mol%, about 43 mol%, and about 44 mol%. It is understood that R'20 can be present in any amount having value between any two foregoing value, for example from about 13 mol% to about 45 mol%, or from about 5 mol% to about 15 mol%, or from about 8 mol% to about 12 mol%.
[74] Similarly to the disclosed above compositions, wherein A1203 is present from about 5 mol% to about 7.5 mol %, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase and from about 20 to about 80% of the petalite phase. While in other aspects, when A1203 is present from about 5 mol% to about 7.5 mol % and L120 is present from mol% to about 25 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the ii-spodumene phase and from about 20 to about 80% of the petalite phase, and a minor phase comprises up to 10 mol% of the lithium silicate phase. In yet still, further aspects, when A1203 is present from about 7 mol% to about 12 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the 13-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase, if R'20 comprises Li.20.
[75] In still further aspects, the amount of R'20 can be adjusted to provide glass compositions exhibiting desired melting temperature and/or liquidus temperatures.
Without being bound by theory, the addition of alkali oxides, for example, can increase the coefficient of thermal expansion (GTE) and/or lower the chemical durability of the glasses and/or glass-ceramics that include such precursor glass compositions. The amount of excess alkali in a glass composition can also determine the ceramming or heat treatment temperature used to form the glass-ceramics.
[761 In still further aspects, such ion-exchanged glass-ceramic compositions can further comprise: a) from 0 mol% to about 8 mol% of 8203, b) from 0 mol% to about 8 mol% of Zr02, c) from 0 mol% to about 5 mol% of P205, and d) from 0 mol% to about 5 mol% of Na20. While, in other aspects, the glass-ceramic compositions as disclosed herein can further comprise a) from 0 mol% to about 5 mol% of 8203, b) from 0 mol% to about 3 mol% of Zr02, c) from 0 mol% to about 3 mol% of P205, and d) from 0 mol% to about 3 mol% of Na20.
(77] In such exemplary aspects, the 8203 can be present in any amount from 0 mo10/0 to about 8 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about 4 mol%, about 5 mol%, about 6 mol%, and about 7 mol%. It is understood that 8203 can be present in any amount having a value between any two foregoing values, for example, from about 0.1 mol% to about 5 mol%, from about 0.1 mol% to about 3 mol%, or from about 0.1 mol% to about 2 mol%.
[78] In further aspects, the Zr02 can be present in any amount from 0 mol% to about 8 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mar/0, about 1 mol%, about 2 mol%, about 3 mol%, about 4 ince/0, about 5 mol%, about 6 mol%, and about 7 mol%. It is understood that ZrO2 can be present in any amount having a value between any two foregoing values, for example, from 0 mol% to about 3 morY0, or from about 0.1 mol% to about 6 mol%, or from about 2 mol% to about 6 mol%.
[791 In further aspects, the P205 can be present in any amount from 0 mol% to about 5 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about and 4 mol%. It is understood that P205 can be present in any amount having a value between any two foregoing values, for example, from 0 mol% to about 3 mol%, or from about 0.1 mol% to about 5 mol%, or from about 1 mol% to about 5 mol%.
DM In further aspects, the Na20 can be present in any amount from 0 mol% to about 5 mol%, including exemplary values of about 0.01 mol%, about 0.05 mol%, about 0.1 mol%, about 0.5 mol%, about 1 mol%, about 2 mol%, about 3 mol%, about and 4 mol%. It is understood that Na2O can be present in any amount having a value between any two foregoing values, for example, from 0 mol% to about 3 mol%, or from about 0.1 mol% to about 2 mol%, or from about 1 mol% to about 5 mol%.
(811 In yet further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit density from about 2.00 9/cm3 to about 2.6 g/cm3, including exemplary value of about 2.01 g/cm3, about 2.02 g/cm3, about 2.03 g/cm3, about 2.04 g/cm3, about 2.05 g/cm3, about 2.06 g/cm3, about 2.07 g/cm3, about 2.08 gicm3, about 2.09 g/cm3, about 2.1 9/cm3, about 2.11 9/cm3, about 2.12 g/cm3, about 2.13 g/cm3, about 2.14 g/cm3, about 2.15 g/cm3, about 2.16 g/crn3, about 2.17 g/cm3, about 2.18 9/cm3, about 2.19 g/cm3, about 2.20 g/cm3, about 2.21 g/cm3, about 2.22 g/cm3, about 2.23 g/cm3, and about 2.24 g/cm3, about 2.25 g/cm3, about 2.26 g/cm3, about 2.27 g/cm3, about 2.28 g/cm3, about 2.29 g/cm3, about 2.30 g/cm3, about 2.31 g/cm3, about 2.32 g/cm3, about 2.33 g/cm3, and about 2.34 g/cm3, about 2.35 g/cm3, about 2.36 g/cm3, about 2.37 g/cm3, about 2.38 9/cm3, about 2.39 g/cm3, about 2.4 g/cm3, about 2.41 g/cm3, about 2.42 9/cm3, about 2.43 g1cm3, about 2.44 g/cm3, about 2.45 g/cm3, about 2.46 g/cm3, about 2.47 g/cm3, about 2.48 g/cm3, about 2.49 g1cm3, about 2.5 g/cm3, about 2.51 g/cm3, about 2.52 9/cm3, about 2.53 g/cm3, about 2.54 g/cm3, about 2.55 g/cm3, about 2.56 g/cm3, about 2.57 g/cm3, about 2.58 9/cm3, and about 2.59 g/cm3.
(82] In still further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit an average transmittance greater than about 80% over a wavelength range from about 390 nm to about 700 nm as measured for a sample prepared from the composition and having a thickness of about 2.00 mm. In such exemplary aspects, the average transmittance can be greater than about 81%, about 82%, about 83%, about 84%, about 85%, about 86 %, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 99.5%, and about 99.99%. In still further aspects, the average transmittance is measured over a wavelength range from about 390 nm to about 700 nm, including exemplary values of about 400 nm, about 450 nm, about 500 nm, about 550 nm, about 600 nm, and about 650 nm. It is understood that in such exemplary aspects, the glass-ceramic composition is substantially transparent. In yet other aspects, the glass-ceramic composition is transparent. In still further exemplary aspects, the glass-ceramic composition comprises a plurality of crystal grains, wherein the median size of a crystal grain is from about 20 to about 80 nm, including exemplary values of about 25 nm, about nm, about 35 nm, about 40 nm, about 45 nm, about 50 nm, about 55 nm, about 60 nm, about 65 nm, about 70 nm, and about 75 nm.
(83] In yet other aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit an average transmittance between 20% and 80% over a wavelength range from about 390 nm to about 700 nm as measured for a sample prepared from the composition and having a thickness of about 2.00 mm. In such exemplary aspects, the average transmittance is about 20%, about 25%, about 30%, about 35, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75% and about 80%. In still further aspects, the average transmittance is measured over a wavelength range from about 390 nm to about 700 nm, including exemplary values of about 400 nm, about 450 nm, about 500 nm, about 550 nm, about 600 nm, and about 650 nm. It is understood that in such exemplary aspects, the glass-ceramic composition is substantially translucent. In yet other aspects, the glass-ceramic composition is translucent. In still further exemplary aspects, the glass-ceramic composition comprises a plurality of crystal grains, wherein the median size of a crystal grain is from about 80 to about 500 nm, including exemplary values of about 100 nm. about 120 nm, about 150 nm, about 170 nm, about 200 nm, about 220 nm, about 250 nm, about 270 nm, about 300 nm, about 320 nm, about 350 nm, about 370 nm, about 400 nm, about 420 nm, about 450 nm, and about 470 nm.
[84] In yet other aspects, any of the disclosed herein glass-ceramic compositions(both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit an average transmittance lower than 20% over a wavelength range from about 390 nm to about 700 nm as measured for a sample prepared from the composition and having a thickness of about 2.00 mm. In such exemplary aspects, the average transmittance is about 20%, about 19%, about 18%, about 17, about 16%, about 15%, about 14%, about 13%, about 12%, about 11%, about 10%, about 9%, about 8%, about 7, about 6%, about 5%, about 4%, about 3%, about 2%, and about 1%. In still further aspects, the average transmittance is measured over a wavelength range from about 390 nm to about 700 nm, including exemplary values of about 400 nm, about 450 nm, about 500 nm, about 550 nm, about 600 nm, and about 650 nm. It is understood that in such exemplary aspects, the glass-ceramic composition is substantially opaque. In yet other aspects, the glass-ceramic composition is opaque. In still further exemplary aspects, the glass-ceramic composition comprises a plurality of crystal grains, wherein the median size of a crystal grain is greater than about 500 nm, greater than about 550 rim, greater than about 600 nm, greater than about 650 nm, greater than about 700 nm, greater than about 750 nm, greater than about 800 nm, greater than about 850 nm, greater than about 900 rim, greater than about 950 rim, or greater than about 1,000 nm.
[851 In still further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit Vickers hardness equal to or greater than about 6.0 GPa, or greater than about 7 GPa, or greater than about 8 GPa, or greater than about 9 GPa, or greater than about 10 GPa.
[86] In still further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit Vickers hardness of at least about 5% greater than Vickers hardness of a standard soda lime silicate glass, or at least about 7% greater, at least about 10% greater, at least about 15% greater, at least about 20% greater, at least about 25 % greater, or at least about 50% greater than Vickers hardness of a standard soda lime silicate glass.
[871 In still further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit a crack-resistance greater than about 0.2 kgf, about 0.4 kgf. about 0.6 kgf, about 0.8 kgf, or greater than about 1 kgf, or greater than about 1.5 kgf, greater than about 2 kgf, greater than about 5 kgf, or greater than about 10 kgf. In still further exemplary aspects, the glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) disclosed herein can exhibit a crack-resistance that at least 4 times higher, at least 5 times higher, at least 6 times higher, at least 7 times higher, at least 8 times higher, at least 9 times higher, or at least 10 times higher than a crack-resistance of a standard soda lime silicate glass.
[88] In still further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can exhibit a thermal expansion coefficient from about 40x107 to about 90x107 Pc, including exemplary values of about 41x1 07/ C, about 42x107 / C, about 43x107 1 C, about 44x1 / C, about 45x10-7 1 C, about 46x107 1 C, about 47x107 / C, about 48x1 1 C, about 49x10-7 PC, about 50x10-7/"C, about 51x107 1 C, about 52x10-71 C, about 53x10-7/ C, about 54x10-7 PC, about 55x107 / C, about 56x1 , about 57x107 / C, about 58x10-7 1 C, about 59x107 1 C, about 60x107 / C, about 61x107 / C, about 62x10-7/ C, about 63x10-7 PC, about 64x107 / C, about 65x104 1 C, about 66x104 1 C, about 67x10-7 / C, about 68x107 1 C, about 69x10-/ C, about 70x107/ C, about 71x10-7/0C, about 72x1071 C, about 73x107 / C, about 74x10-7/ C, about 75x10-7/ C, about 76x10-7/ C, about 77x10-7/ C, about 78x10-1 C, about 79x1071 C, about 80x107 / C, about 81x10.7 1 C, about 82x107 / C, about 83x104 1 C, about 84x1041 C, about 85x10.7 1 C, about 86x104 1 C, about 87x104 1 C, about 88x10.7 1 C, and about 89x107 PC. It is understood that in such aspects, C is averaged over a temperature range from about 25 C to about 300 C. It is understood that the glass-ceramic compositions can comprise any thermal expansion value between any two foregoing values.
[891 In yet further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) comprises a glass transition temperature (Tg) from about 450 C
to about 600 CC, including exemplary values of about 460 C, about 470 C, about C, about 490 C, about 500 C, about 510 C, about 520 C, about 530 C, about 540 C, about 550 C, about 560 C, about 570 C, about 580 C, and about 590 C.
(90] In still further aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can comprise one or more fining agents. In certain aspects, the compositions can comprise from greater than 0 mol% to about 1 mol% of a fining agent, including exemplary value of about 0.1 mole%, about 0.2 mol%, about 0.3 mol%, about 0.4 mol%, about 0.5 mol%, about 0.6 mol%, about 0.7 mol%, about 0.8 mol%, and about 0.9 mol%. It is understood that the fining agent can be present in any amount having a value between any two foregoing values.
[911 In still further aspects, the fining agent can comprise any fining agent known in the art. In certain aspects, the fining agent can comprise a salt, a metallic oxide, or any combination thereof. In certain aspects, where the fining agent comprises a salt, such salt can comprise sulfate, chloride, iodide, bromide, or a combination thereof.
Yet in further aspects, where the fining agent comprises a metal oxide, the metal oxide can comprise Ce02, Sn02, Fe2O3, A5203, Sb203, Mn02, or a combination thereof. However, in yet other aspects, the glass composition does not comprise any heavy metals. In such aspects, the glass composition is substantially free of heavy metals.
[92] In certain aspects, the addition of the fining agent can reduce bubble formation in glass melts to reduce the population of bubbles in the glass-ceramics.
[93] It is understood that in some aspects, any of the disclosed herein glass-ceramic compositions (both glass-ceramic compositions and ion-exchanged glass-ceramic compositions) can also comprise other components. For example, and without limitations, the disclosed compositions can comprise one or more coloring components. In such aspects, the one or more of coloring components are selected from transition metal oxides and/or rare earth metal oxide. For example, and without limitations, the one or more of coloring components can comprise V205, Cr203, Ti02, Mn02, MO, ZnO, CuO, C0304, and combinations thereof. In aspects where the coloring components are present, these components are present in a total amount equal to or less than about 1 mol%, less than about 0.9 mol%, less than about 0.8 mol%, less than about 0.7 mol%, less than about 0.6 mol%, less than about 0.5 mol%, less than about 0.4 mork, less than about 0.3 mol%, less than about 0.2 mol%, less than about 0.1 mol%. It is understood that the coloring components can be present in any amount having a value between any two foregoing values.
[94] In still further aspects, to avoid a possible undesired coloring effect on the disclosed herein glass-ceramic compositions, some trace amounts of decolorizing agents can be added. In such aspects, the decolorizing agents can comprise one or more of sodium sulphate, selenium compounds, erbium oxide, cerium oxide, cobalt oxide, manganese oxide, and other polyvalent elements. In still further aspects, these decolorizing agents can reduce colorization through any mechanisms known in the art, including chemical and/or physical mechanisms. In yet still further aspects, these agents can be present in a total amount equal to or less than about 1 mol%, less than about 0.9 mol%, less than about 0.8 mol%, less than about 0.7 mol%, less than about 0.6 mol%, less than about 0.5 mol%, less than about 0.4 mol%, less than about 0.3 mol%, less than about 0.2 mor/o, less than about 0.1 mol%, less than about 0.05 mol%, or less than about 0.01 mol%. It is understood that the decolorizing agents can be present in any amount having a value between any two foregoing values.
[951 In yet further aspects, any of the disclosed herein glass-ceramic compositions can be ion-exchangeable.
(96] In still further aspects, such ion-exchanged glass-ceramic compositions can also be substantially transparent. While in other aspects, such ion-exchanged glass-ceramic compositions are substantially translucent. While in still further aspects, such ion-exchanged glass-ceramic compositions are substantially opaque.
[971 In still further aspects, these ion-exchanged glass-ceramic compositions can comprise a compressive stress layer. It is understood that such a layer is formed by an ion-exchange process.
[98] In still further aspects, when the glass-ceramic compositions comprise R'20, and when R'20 comprises Ag2O, and/or Cu20, and/or CuO, such compositions can also exhibit antimicrobial, antiviral, antibacterial, and/or antifungal properties.
(99] In still further aspects, the glass compositions described herein can be substantially transparent in a wavelength range from about 400 nm to about 800 nm.
In some exemplary and unlimiting aspects, the glass compositions exhibit percent transmittance greater than about 87%, greater than about 88%, greater than about 89%, greater than about 90%, greater than about 91%, greater than about 92%, greater than about 93%, greater than about 94%, greater than about 95%, greater than about 96%, greater than about 97%, greater than about 98%, greater than about 99%, over a wavelength range from about 400 am to about 800 am, including an exemplary value of about 430 am, about 450 am, about 470 nm, about 500 nm, about 530 nm, about 550 nm, about 570 nm, about 600 nm, about 630 nm, about 650 am. about 670 am, about 700 nm, about 730 nm, about 750 nm, and about 770 am.
ARTICLES
000] In certain aspects, disclosed herein are articles comprising any of the disclosed above compositions. For example and without limitations disclosed herein are articles comprising: a) from about 2 mol% to about 20 mol% of Al2O3, b) from about 2 mol% to about 45 mol% of Li2O; and from about 48 mol% to about 80 mol%
of SiO2; having a fi-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase. While in other aspects, disclosed herein are articles comprising: a) from about 3 mol% to about 12 mol% of Al2O3, b) from about 13 mol%
to about 45 mol% of 1..i20; and from about 48 mo10/0 to about 75 mol% of SiO2;
having a ii-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase.
[101] While in still further aspects, disclosed herein are articles comprising: a) from about 2 mol% to about 20 mol% of A1203, b) S102 present from about 48 mol%
to about 80 mol%; and R'20 present from greater than 0 mol% to about 45 mol%;
wherein R'20 comprises Li20, Na20, 1<20, Ag20, Cu20, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase. While in other aspects, disclosed herein are articles comprising: a) from about 3 mol% to about 12 mol% of A1203, b) Si02 present from about 48 mol% to about 75 mol%; and R'20 present from greater than 0 mol% to about 45 mol%; wherein R'20 comprises Li20, Na20, 1<20, Ag20, 0u20, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase.
[102] In certain aspects, also disclosed are glass-ceramic articles comprising compositions having the compressive stress layers. In such exemplary aspects, the compressive stress layer can extend from a surface of the article to a depth of the compressive stress layer, wherein the depth is from about 1 pm to about 100 pm, including exemplary values of about 2 pm, about 5 pm, about 10 pm, about 15 pm, about 20 pm, about 25 pm, about 30 pm, about 35 pm, about 40 pm, about 45 pm, about 50 pm, about 55 pm, about 60 pm, about 65 pm, about 70 pm, about 75 pm, about 80 pm, about 85 pm, about 90 pm, and about 95 pm. In yet further aspects, the depth of the compressive layer can be up to about 25 % of a thickness of the glass-ceramic article, including exemplary values of about 1%, about 5%, about
10%, about 15%, and about 20% of a thickness of the glass-ceramic article.
[103] In still further aspects, the compressive stress layer can exhibit a compressive stress of at least about 10 MPa, at least about 20MPa, at least about 50 MPa, at least about 80 MPa, at least about 100 MPa, at least about 120 MPa, at least about 150 MPa, at least about 180 MPa, at least about 200 MPa, at least about 210 MPa, or at least about 250 MPa.
[104] In still further aspects, the articles disclosed herein exhibit a ring-on-ring strength of at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 35%, or at least 40%, or at least 45%, or at least 50% higher than that of standard soda lime silicate glass tested under similar conditions.
(105] In yet further aspects, the articles can be substantially transparent.
While in other aspects, the articles can be substantially translucent. While still in other aspects, the articles can be substantially opaque. In still further aspects, the articles can comprise compositions comprising a coloring component. In such exemplary aspects, the articles can have a color.
(106] In still further aspects, the articles can comprise any known in the art articles that require the disclosed herein mechanical and optical properties. Yet in other aspects, the articles disclosed herein can comprise a hollowware, tableware, container, plate, sheet (including sheet prepared via the float process), cookware, powder, fiber, cones, spheres, blades, or any combination thereof. In still further aspects, the articles disclosed herein can be formed by any process. For example, the articles can be formed by a float or flat press process, a press-and-blow process, a blow-and-blow process, or any combination thereof. While in still further aspects, disclosed herein articles can also be used in a variety of electronic devices or portable computing devices, light diffusers, automotive, appliances, medical industry, food industry, and even architectural applications. In still further aspects, the articles disclosed herein can have known in the art shape or configuration.
[107] Also disclosed herein is a tableware comprising any of the disclosed above glass-ceramic compositions. In certain aspects and without limitations, the tableware can comprise a blown and/or pressed product. In still further exemplary aspects, the tableware can be formed by a press process, a press-and-blow process, a blow-and-blow process, or any combination thereof. In yet other aspects, disclosed herein is a hollowware comprising any of the disclosed above glass-ceramic compositions.
In certain aspects and without limitations, the hollowware can be formed by a press-and-blow process, a blow-and-blow process, or a combination thereof. Also disclosed herein is a cookware comprising any of the disclosed above glass-ceramic compositions. In still further aspects, disclosed herein is a powder comprising any of the disclosed above glass-ceramic compositions. In certain aspects and without limitations, the cookware can be formed by a press process, a press-and-blow process, a blow-and-blow process, or any combination thereof While in other aspects, disclosed herein is a fiber comprising any of the disclosed above glass-ceramic compositions. In certain aspects and without limitations, the fiber can comprise a continuous or discontinuous fiber product or a fiberglass reinforced composite.
METHODS
[108] Also disclosed herein are methods of making the disclosed compositions and the disclosed articles. In certain aspects, disclosed herein is a method comprising: a) forming a mixture comprising from about 2 mol% to about 20 mol%
of A1203, from about 2 mol% to about 45 mol% of Li20; and from about 48 mol% to about 80 mol% of SiO2; b) forming a homogeneous composition; and c) ceramming the homogeneous composition to form a glass-ceramic composition.
[109] Yet in other aspects, disclosed herein is a method comprising: a) forming a mixture comprising from about 3 mol% to about 12 mol% of A1203, from about 13 mol% to about 45 mol% of Li20; and from about 48 mol% to about 75 mol% of Si02;
b) forming a homogeneous composition; and c) ceramming the homogeneous composition to form a glass-ceramic composition.
[110] It is understood that A1203, Li20, and Si0.2 can be present in any amounts as disclosed in the above-described compositions.
[111] In still further aspects, the mixture formed by the methods disclosed herein can further comprise from 0 mol% to about 8 mol% of Zr02, or from 0 mol% to about mol% of P205, or a combination thereof. While in other aspects, the mixture formed by the methods disclosed herein can further comprise from 0 mol% to about 3 mol%
of Z102, or from 0 mol% to about 3 mol% of P205, or a combination thereof. It is understood that both Zr02 and P205 can be present in any amounts as disclosed in the above-described compositions.
[112] In yet further aspects, the step of forming the homogenous composition comprises melting the mixture in a furnace at a temperature from about 1300 CC
to about 1,700 c=C for a first predetermined time. In such temperature the temperature in the furnace can be any temperature in a range from about 1,300 C to about 1,700 C, including exemplary values of about 1,310 C, about 1,320 C, about 1,330 C, about 1,340 C, about 1350 C, about 1,360 C, about 1,370 C, about 1,380 C, about 1,390 C, about 1,400 C, about 1,410 C, about 1,420 C, about 1,430 C, about 1,440 C, about 1,450 C, about 1,460 C, about 1,470 C, about 1,480 C, about 1,490 C, about 1,500 C, about 1,510 C, about 1,520 C, about 1,530 C, about 1,540 C, about 1,550 C, about 1,560 C, about 1,570 C, about 1,580 C, about 1,590 C, about 1,600 C, about 1,610 C, about 1,620 C, about 1,630 C, about 1,640 C, about 1,650 C, about 1,660 C, about 1,670 C, about 1,680 C, and about 1,690 C.
[113] In still further aspects, the methods disclosed herein can further comprise a step of annealing at a temperature from about 450 C to about 700 C, including exemplary values of about 460 C, about 470 C, about 480 C, about 490 C, about 500 CC, about 510 C, about 520 C, about 530 C, about 540 C, about 550 C, about 560 C, about 570 C, about 580 C, about 590 C, about 600 C, about CC, about 620 CC, about 630 C, about 640 C, about 650 C, about 660 C, about 670 C, about 680 C, and about 690 C.
[114] In yet further aspects, the step of ceramming comprises heating the homogenous composition at a nucleation temperature for a second predetermined time. In such exemplary aspects, the nucleation temperature is from 450 C to about 700 C, including exemplary values of about 460 C, about 470 CC, about 480 c about 490 C, about 500 C, about 510 C, about 520 C, about 530 C, about 540 C, about 550 C, about 560 C, about 570 C, about 580 C, about 590 C, about 600 CC, about 620 C, about 630 C, about 640 C, about 650 CC, about 660 C, about 670 cC, about 680 C, about 690 C.
[115] In still further aspects, in the methods disclosed herein, the step of ceramming further comprises a step of heating the composition to a crystallization temperature at a rate from about 5 C/min to about 15 C/min and keeping the composition at the crystallization temperature for a third predetermined time.
In such exemplary aspects, the heating is performed at a rate from about 5 C/min to about 15 C/min, including exemplary aspects, of about 6 C/min, about 7 C/min;
about 8 C/min, about 9 C/min, about 10 C/min, about 11 C/min, about 12 C/min, about 13 C/min, and about 14 C/min.
[116] In still further aspects, the crystallization temperature is from about 580 C to about 800 C, including exemplary values of about 590 C, about 600 C, about C, about 620 C, about 630 C, about 640 ''C, about 650 C, about 660 C, about 670 f'C, about 680 C, about 690 C, about 700 C, about 710 C, about 720 C, about 730 C, about 740 C, about 750 C, about 760 C, about 770 C, about C, and about 790 C.
[117] It is understood that one skilled in the art can adjust the nucleation and crystallization temperatures to accommodate the different glass compositions within the above-described range.
[118] In yet further aspects, the first predetermined time is from about 0.5 hours to about 20 hours, including exemplary values of about 1 hour, about 1.5 hours, about 2 hours, about 2.5 hours, about 3 hours, about 3.5 hours, about 4 hours, about 4.5 hours, about 5 hours, about 5.5 hours, about 6 hours, about 6.5 hours, about 7 hours, about 7.5 hours, about 8 hours, about 9.5 hours, about 10 hours, about 10.5 hours, about 11 hours, about 11.5 hours, about 12 hours, about 12.5 hours, about 13 hours, about 13.5 hours, about 14 hours, about 14.5 hours, about 15 hours, about 15.5 hours, about 16 hours, about 16.5 hours, about 17 hours, about 17.5 hours, about 18 hours. about 18.5 hours, about 19 hours, and about 19.5 hours.
[119] In yet further aspects, the first predetermined time is from about 3 hours to about 5 hours, including exemplary values of about 3.1 hours, about 3.2 hours, about 3.3 hours, about 3.4 hours, about 3.5 hours, about 3.6 hours, about 3.7 hours, about 3.8 hours, about 3.9 hours, about 4.0 hours, about 4.1 hours, about 4.2 hours, about 4.3 hours, about 4.4 hours, about 4.5 hours, about 4.6 hours, about 4.7 hours, about 4.8 hours, and about 4.9 hours.
[120] In yet further aspects, the second predetermined time is from about 0.5 hours to about 20 hours, including exemplary values of about 1 hour, about 1.5 hours, about 2 hours, about 2.5 hours, about 3 hours, about 3.5 hours, about 4 hours, about 4.5 hours, about 5 hours, about 5.5 hours, about 6 hours, about 6.5 hours, about 7 hours, about 7.5 hours, about 8 hours, about 9.5 hours, about hours, about 10.5 hours, about 11 hours, about 11.5 hours, about 12 hours, about 12.5 hours, about 13 hours, about 13.5 hours, about 14 hours, about 14.5 hours, about 15 hours, about 15.5 hours, about 16 hours, about 16.5 hours, about 17 hours, about 17.5 hours, about 18 hours, about 18.5 hours, about 19 hours, and about 19.5 hours.
[121] In yet further aspects, the second predetermined time is from about 3 hours to about 5 hours, including exemplary values of about 3.1 hours, about 3.2 hours, about 3.3 hours, about 3.4 hours, about 3.5 hours, about 3.6 hours, about 3.7 hours, about 3.8 hours, about 3.9 hours, about 4.0 hours, about 4.1 hours, about 4.2 hours, about 4.3 hours, about 4.4 hours, about 4.5 hours, about 4.6 hours, about 4.7 hours, about 4.8 hours, and about 4.9 hours.
[122] In yet further aspects, the third predetermined time is from about 0.5 hours to about 20 hours, including exemplary values of about 1 hour, about 1.5 hours, about 2 hours, about 2.5 hours, about 3 hours, about 3.5 hours, about 4 hours, about 4.5 hours, about 5 hours, about 5.5 hours, about 6 hours, about 6.5 hours, about 7 hours, about 7.5 hours, about 8 hours, about 9.5 hours, about 10 hours, about 10.5 hours, about 11 hours, about 11.5 hours, about 12 hours, about 12.5 hours, about 13 hours, about 13.5 hours, about 14 hours, about 14.5 hours, about 15 hours, about 15.5 hours, about 16 hours, about 16.5 hours, about 17 hours, about 17.5 hours, about 18 hours, about 18.5 hours, about 19 hours, and about 19.5 hours.
[123] In yet further aspects, the third predetermined time is from about 3 hours to about 5 hours, including exemplary values of about 3.1 hours, about 3.2 hours, about 3.3 hours, about 3.4 hours, about 3.5 hours, about 3.6 hours, about 3.7 hours, about 3.8 hours, about 3.9 hours, about 4.0 hours, about 4.1 hours, about 4.2 hours, about 4.3 hours, about 4.4 hours, about 4.5 hours, about 4.6 hours, about 4.7 hours, about 4.8 hours, and about 4.9 hours.
[124] In yet further aspects, the first, second, and/or third predetermined times can be the same or different.
[125] In certain aspects, in the methods disclosed herein, P205 can behave as a nucleation agent. As used herein, the term a "nucleation agent" refers to a component in the glass-ceramics (and/or the precursor glass composition and/or glass that includes such a composition) that serves as the starting point of the nuclei itself (i.e, is a discontinuity or defect in the homogenous or amorphous phase from which the crystal phase is generated), and does not require other components to promote nucleation. It is understood that in other exemplary aspects, also TiO2 and/or ZrO2 can also be used as the nucleation agents.
[126] While in other aspects, ZrO2 can be a crystal size growth- limiting agent.
[127] Also disclosed herein are aspects where the glass-ceramic compositions formed by the disclosed herein methods can comprise p-spodumene phase, optionally petalite phase, and a lithium silicate crystalline phase.
[128] In still further aspects, the glass-ceramic composition formed by the disclosed methods can comprise Al2O3 in an amount from about 5 mo10/0 to about 7.5 mol 0/0, including exemplary values of about 5.1 mol%, about 5.2 mol%, about 5.3 mol%, about 5.4 mol%, about 5.5 mol%, about 5.6 mol%, about 5.7 mol%, about 5.8 mol%, about 5.9 mol%, about 6.0 mol%, about 6.1 mol%, about 6.2 mol%, about 6.3 mol%, about 6.4 mol%, about 6.5 mol%, about 6.6 mol%, about 6.7 mol%, about 6.8 rriol /0, about 6.9 mol%. about 6.9 rnal%, about 7.0 mol%, about 7.1 mol%, about 7.2 mol%, about 7.3 mol%, and about 7.4 mol%. In such exemplary values, the glass-ceramic article comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase, including exemplary values of 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, and about '75% of the p-spodumene phase. In still further aspects, the major phase can comprise from about 20 to about 80% of the petalite phase 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, and about 75% of the p-spodumene phase. In still further aspects, such compositions can comprise a minor crystalline phase comprising up to about 10% of the lithium silicate phase, including exemplary values of about 0.01(%, about 0.05%, about 0.1%, about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 9.5, and about 9.99%.
[129] In yet further exemplary aspects, when Al2O3 is present from about 5 mol%
to about 7.5 mot 0/0, Li2O can be present from about 20 mol% to about 25 mol%, including exemplary values of about 21 mol%, about 21.5 mol%, about 22 mol%, about 22 5 mol%, about 23 mol%, about 23.5 mol%, about 24 molok, and about 24.5 mol%.
[130] In still further aspects, the glass-ceramic composition formed by the disclosed methods can comprise A1203 in an amount from about 7 mol% to about mol%, including exemplary values of about 7.1 mol%, about 7.2 mol%, about 7.3 mol%, about 7.4 mol%. about 7.5 mol%, about 7.6 mol%, about 7.7 mol%, about 7.8 mol%, about 7.9 mol%, about 8.0 mol%, about 8.1 mol%, about 8.2 mol%, about 8.3 mol%, about 8.4 mol%, about 8,5 mol%, about 8.6 mol%, about 8.7 mol%, about 8.8 mol%, about 8.9 moi%, about 9.0 mol%, about 9.1 mol%, about 9.2 mol%, about 9.3 mol%, and about 9.4 mol%, about 9.5 mol%, about 9.6 mol%, about 9.7 mol%, about 9.8 mol%, about 9.9 mol%, about 10.0 mol%, about 10.1 mol%, about 10.2 mol%, about 10.3 mol%, about 10.4 mol%, about 10.5 mol%, about 10.6 mol%, about 10.7 mol%, about 10.8 mol%, about 10.9 mol%, about 11.00 mol%, about 11.1 mol%, about 11.2 mol%, about 11.3 mol%, about 11.4 mol%, about 11.5 mol%, about 11.6 mol%, about 11.7 mol%, about 11.8 mol%, and about 11.9 mol%. In such exemplary aspects, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the 0-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase. In such aspects, the major crystalline phase can comprise from about 60% to about 90%
of the 0-spodumene phase, including exemplary values of about 65%, about 70%, about 75%, about 80%, and about 85% of the p-spodumene phase. While in other aspects, the minor crystalline phase comprising up to about 10% of the lithium silicate phase, including exemplary values of greater than 0%, about 0.01%, about 0.05%, about 0.1%, about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 9.5%,about 9.9%, and about 9.99%. In still further aspects, when the lithium silicate crystalline phase is present, it can comprise a lithium metasilicate crystalline phase.
[131] In still further aspects, the mixture formed by the disclosed herein compositions can further comprise from about from 0 mol% to about 8 mol% of 8203, and from 0 mol% to about 8 mol% of Na20. While in still further aspects, the mixture formed by the disclosed herein compositions can further comprise from about from 0 M01% to about 5 mol% of B203, and from 0 mol% to about 3 mol% of Na2O. It is understood that both 8203 and Na20 can be present in any amounts, as disclosed in the above-described compositions.
[132] In still further aspects, the methods disclosed herein can comprise a step of ion-exchange treatment comprising placing the glass-ceramic composition into a molten salt bath. In such aspects, the molten salt bath can comprise any ions that can be used for an ion-exchange of the glass-ceramic composition. In certain aspects, the molten bath can comprise sodium, potassium, silver, or copper (I) ions, or a combination thereof. In still other aspects, the ion-exchange treatment can be performed at conditions effective to provide an ion-exchanged glass-ceramic composition.
[133] In still further aspects, the molten bath can comprise any of the disclosed ions or their mixtures. In certain aspects, the conditions effective to provide the ion-exchanged glass-ceramic composition comprise exposure of the glass-ceramic composition to a molten salt at a temperature from about 380 C to about 500 including exemplary values of about 390 C, about 400 C, about 410 C, about C, about 430 C, about 440 C, about 450 C, about 460 C, about 470 C, about 480 C, and about 490 C and for a time period from about 4 hours to about 20 hours, including exemplary values of about 5 hours, about 6 hours, about 7 hours, about 8 hours, about 9 hours, about 10 hours, about 11 hours, about 12 hours, about 13 hours, about 14 hours, about 15 hours, about 16 hours, about 17 hours, about 18 hours, and about 19 hours.
[134] In some further exemplary and unlimiting aspects, the step of ion exchange treatment can be done after the step of ceramming.
351 It is further understood that in aspects disclosed herein, the step of ion-exchange treatment can comprise placing the disclosed herein composition in a first molten bath comprising one or more molten oxides and forming a first ion-exchanged composition. While in other aspects, the methods can further comprise placing the first-ion exchanged composition in a second bath comprising one or more molten oxide and forming a second ion-exchanged composition, and so on until the desired ion-exchanged composition is formed. It is understood that in these exemplary and unlimiting aspects, the first and the second molten bath compositions can comprise the same or different molten oxides In yet other aspects, the desired ion-exchanged composition can be formed in one step. In some exemplary aspects, the molten bath comprising potassium (K) ions (or silver (Ag) or copper (Cu) (I)) or Cu (II) can replace sodium (Na) ions or lithium (Li) ions in the glass-ceramic composition depending on the temperature conditions. In yet other exemplary aspects, the molten bath comprising sodium (Na) ions can further replace lithium (Li) ions in the glass-ceramic composition depending on the temperature conditions. In still further aspects, other alkali metal ions such as cesium or rubidium can also be present. In yet other exemplary and unlimiting aspects, the ion-exchange can also be done with divalent metal ions, such as calcium, barium, or magnesium, if desired. It is also understood that the molten baths can comprise any known in the art salts of the desired metal ions, for example, the salts can comprise nitrates, sulfates, halides, and the like.
[136] It is further understood that any known in the art mechanisms of the ion-exchange can be contemplated. In certain aspects, larger ions in the composition can be replaced with the smaller ions in the bath. Yet, in further aspects, the smaller ions the compositions are replaced with larger ions on the bath. Such ion-exchange processes can be controlled by tuning the temperature and exposure time.
(137] In yet further aspects, when the bath comprises silver or copper ions, the formed ion-exchanged compositions can exhibit antimicrobial, antibacterial, antifungal, or antiviral properties to the material.
[138] In still further aspects, the ion-exchanged glass-ceramic composition comprises: a) Al2O3 present from about 2 mol% to about 20 mol%; b) SiO2 present from about 48 mol% to about 80 mol%; R'20 present from greater than 0 mol% to about 45 inol%, and wherein R'20 comprises Li2O, Na2O, K20, Ag2O, Cu2O. CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase. While yet on other aspects, the ion-exchanged glass-ceramic composition comprises: a) Al2O3 present from about 3 mol% to about 12 mol%; b) SO2 present from about 48 mol%
to about 75 mol%; c) R'20 present from greater than 0 mol% to about 45 mol%;
and wherein R'20 comprises Li2O, Na2O, 1<20, Ag20, Cu20, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase. It is understood that any of the components disclosed herein can comprise any amounts as disclosed in mentioned above compositions.
[139] In still further aspects, the methods disclosed herein provide for the ion-exchanged glass-ceramic composition comprising a compressive stress layer. It is understood that the compressive stress layer formed by the disclosed methods can exhibit any properties described above and have any thickness or depth as described above. In yet further aspects, the properties of the compressive stress layer can be tuned by various ion-exchange treatment steps, such as a single ion-exchange step or multiple ion-exchange procedures, as described above.
[140] It is further understood that in certain aspects, the amount and a type of ions added through the ion-exchange can affect the transparency of the composition.
Yet, in other aspects, the amount and a type of ions added through the ion-exchange can affect the coefficient of thermal expansion (CTE) of the composition. VVithout being bound by theory, the addition of alkali oxide, for example, can increase the coefficient of thermal expansion (CTE) and/or lower the chemical durability of the glasses and/or glass-ceramics.
[141] In still further aspects, the glass-ceramic compositions and the ion-exchanged glass-ceramic compositions can exhibit any of the disclosed above characteristics and properties. In such exemplary aspects, these compositions can be transparent, translucent, or opaque and have any of the disclosed above medium grain sizes.
[142] In still further aspects, the methods disclosed herein comprise a step of forming a glass-ceramic article. Any known in the art methods of forming or shaping an article can be utilized. For example, and without limitation, the methods of forming a glass-ceramic article can comprise down drawing (by either a slot draw or fusion draw process), float processing, or thin rolling the glass. In yet other aspects, the methods can comprise shaping the glass or glass-ceramic to any desired shape.
Various shaping methods can also be used, such as casting, molding, pressing, rolling, floating, and the like. In yet further aspects, the articles disclosed herein can be formed by a float/flat glass press process, a press-and-blow process, a blow-and-blow process, or any combination thereof [143] In still further aspects, the articles formed by the disclosed herein methods can comprise a hollowware, tableware, container, plate, sheet, float/flat sheet, cookware, powder, fiber, cones, spheres, blades, or any combination thereof.
EXAMPLES
[144] The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the compounds, compositions, articles, devices, and/or methods claimed herein are made and evaluated and are intended to be purely exemplary and are not intended to limit the disclosure. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.), but some errors and deviations should be accounted for.
1:14.5] The LAS glass-ceramics samples were prepared using the powder of Li2CO3 (Alfa Aesar, USA, 99%), SiO2 (Alfa Aesar, USA, 99.5%), Al2O3 (Alfa Aesar, USA, 99.5%), H3B03(Acros Organics, USA, 99+%), Na2CO3(J.T.Baker, USA), Al(P03)3 (Alfa Aesar, USA), ZrO2 (Fisher Chemical, USA). The compositions of Li2CO3, SiO2, and Al2O3 are mainly based on the phase diagram of Si02-A1203-Li20 (as shown in FIG. 1, M. Krishna Murthy et al., Phase equilibria in the system lithium metasilicate¨
f3-eucryptite, J. Am. Ceram, Soc. 37 (1) (1954) 14-17). As the compositions of the residue glass are different from those of crystals, the gradient of Li2O and Al2O3 was investigated to maximize the percent of petalite and fi-spodumene crystals in final glass-ceramics. P205 was used as a nucleation agent to introduce bulk nucleation and accelerate the nucleation rate of crystal phases, and ZrO2 was used to limit the crystal size to obtain transparency. Different amounts of P203 and ZrO2 were investigated to change numbers and sizes of crystals in order to optimize transparency and increase mechanical strength. B203 and N820 were used to promote glass-forming abilities. The compositions of the various glass-ceramic samples as prepared herein are shown in Table 1.
11461 In this example, mixtures of 200 g powders were double melted in a platinum crucible at 1,550 '-=C and kept for 3 and 5 h for homogenization and fining.
Molten glasses were poured on a stainless-steel plate, annealed at 520 C for more than 8 h, and slowly cooled to room temperature in the furnace to release thermal stress. The homogeneity was verified using Polariscope to avoid unwanted nucleation and crystal growth in glass-ceramics.
[147] Glass samples were cut into small pieces and prepared for ceramming.
Different temperatures were selected for nucleation temperature, in a small range above the glass transition temperature (Tg) measured by Differential Scanning Calorimetry (DSC). Different were selected for crystal growth, according to the crystallization temperature measured by DSC. Small glass pieces were kept at nucleation temperature for 4 h, increased to crystal growth temperature at 10 C/min, held for 4 h for crystal growth, and slowly cooled down to room temperature in the furnace.
[148] Glass samples were ground into a powder and measured by Inductively Coupled Plasma Atomic Emission Spectroscopy (ICP-AES) to investigate the compositional differences between glass samples and batch materials. DSC
measurement performed heat-cool-heat experiments at 10 C/min using SDT 600 from TA company to learn glass transition temperature and crystallization temperature. The cooling process provides a known thermal history, and Tg was recorded as the onset temperature in the glass transition area. Viscosity-temperature parameters were measured using a rotational viscometer (VIS 403, TA
Instruments) at a 20 K/min cooling rate in the range of 10 3-10" Pa-s. The observed high cooling rate was assumed to be due to the crystallization of the supercooled liquid of lithium aluminosilicate glass.
[149] Densities of both glass and glass-ceramics were measured using the Archimedes method with distilled water as a liquid medium at room temperature.
X-ray diffraction (XRD) patterns (20 from 10 to 70 ) were obtained to identify crystal phases and calculate the percent of different crystals using PANalytical Empryean X-ray Diffractometer with Cu Ka radiation (40 kV& 40 rnA) source.
[150] Ultraviolet-visible (UV-VIS) transmittance spectra in a range from 250 to 800 nm were obtained using Perkin-Elmer Lambda 950 UV-VIS-NIR Spectrophotometer.
The glass-ceramics samples for UV-VIS spectra were optically polished to equal thickness (2.0 0.1 mm).
Table 1. The composition of LAS glass-ceramics batch materials.
LAS.11-6 LAS7 LASS LAS9 LAS10 LAS11 LAS12 mol% mol% mol% mol% mol% mol% mol%
S102 68.3 69.5 67.1 65.9 68.3 68.3 68.3 A1203 9.4 9.4 9.4 9.4 5.4 7.4 3.4 B203 0.6 0.6 0.6 0.6 0.6 0.6 0.6 L120 18.5 18.5 18.5 18.5 22.5 20.5 24.5 Na2O 1.6 1.6 1.6 1.6 1.6 1.6 1.6 K20 0.0 0.0 0.0 0.0 0.0 0.0 0.0 Zr02 1.2 0.0 2.4 3.6 1.2 1.2 1.2 P205 0.6 0.6 0.6 0.6 0.6 0.6 0.6 Total 100 100 100 100 100 100 100 mol% mol% mol% mol% mol% mol% mol%
SiO2 68.3 67.1 67.1 67.1 68.9 66.9 64.9 A1203 11.4 7.4 5.4 3.4 5.4 5.4 5.4 8203 0.6 0.6 0.6 0.6 0.0 2.0 4.0 Li2O 16.5 20.5 22.5 24.5 22.5 22.5 22.5 N a20 1.6 1.6 1.6 1.6 1.6 1.6 1.6 K20 0.0 0.0 0.0 0.0 0.0 0.0 0.0 Zr02 1.2 2.4 2.4 2.4 1.2 1.2 1.2 P20s 0.6 0.6 0.6 0.6 0.6 0.6 0.6 Total 100 100 100 100 100 100 100 mol% mol% mol% mol% mol% mol% mol%
Si02 68.9 67.7 67.1 67.7 68.3 68.3 69.1 A1203 5.4 9.4 5.4 5.4 6.4 4.4 7.4 B203 0.6 0.6 0.6 0.6 0.6 0.6 0.6 Li20 22.5 18.5 22.5 22.5 21.5 23.5 18.5 N a20 1.6 1.6 1.6 1.6 1.6 1.6 1.6 K20 0.0 0.0 0.0 0.0 0.0 0.0 0.0 ZrO2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 P205 0.0 1.2 1.8 1.2 0.6 0.6 1.8 Total 100 100 100 100 100 100 100 [151] Vickers hardness and toughness were determined by using a Mitutoyo HM-200 microhardness tester. At least 10 indents were measured on the polished surface of each sample under a 136 diamond indenter. The hardness was measured under 0.1 kgf (1 kgf=9.8 N) and calculated following Equation (1):
1-117 = 0.0182-1Laz (1);
d t where HV is the Vickers hardness in GPa, F is the load in kgf, and dr and d2 are the lengths of two diagonals left by indenter in mm. Vickers toughness was measured under 0.8 kgf and calculated using Equation (2):
_6 (E)" P
= 0.016 x 10 ¨FT (-)1. (2);
co 5 where Kic is the indentation fracture toughness in MPa=m", E is the elastic Young's modulus in GPa, H is the hardness in GPa, P is the load in N, Co is half of the diagonal crack length in m. Elastic modulus is measured using nanoindentation.
Indentation test is used for fracture toughness, instead of three-point bending test in current research, for the reason of low dimensional requests and fewer sample numbers.
[152] It was found that the number of cracks in the indentation test increases with increasing load following the sigmodal-like shape. Weibull's equation was used to fit the curve of sodium aluminosilicate glasses by Yoshida et al. and calcium aluminosilicate glasses by POnitzsch at al. (Yoshida. A. at al., Crack initiation behavior of sodium aluminosilicate glasses. J. of Non-Cryst. Solids 344 (1-2) (2004) 37-43; A. POnitzsch et al., Bulk elastic properties, hardness, and fatigue of calcium aluminosilicate glasses in the intermediate-silica range. J. of Non-Cryst.
Solids 434 (2016) 1-12).
[153] Weibull's equation is shown in Equation (3):
F(P) = I ¨ exp [¨ (Er (3) where F(P) is the probability of cracks (the number of ideal cracks divided by four), P
is the load, p is the scale parameter, and m is the Weibull modulus. The crack resistance is defined as F(P)=0.5, meaning the load required to generate two out of four cracks.
[154] Linear thermal expansion coefficient (CTE) of glass-ceramics samples were obtained under 0.0500 N force using a Thermomechanical Analyzer (TMA) Q400 from the TA company. The samples were ground to 6x6x20 mm, and heated from room temperature to 300 C at a 5 C /min heating rate.
Glass composition [155] It was found that the composition from 1CP data is very close to that of batch materials, with an error of less than 0.5 mol% for major oxides and 0.2 mol%
for minor oxides. Due to the evaporation loss, the amounts of P205, 1.120, B203 were found to be less than that of the batch materials, causing the increasing percent of 6102 and A1203 in glass compositions. Due to the large atomic mass and high melting point, the amount of Zr02 in the glass was found to be slightly less than that in the batch materials.
Crystal phases [156] It was further found that the types of the crystal phases from the XRD
pattern mainly change with the amount of A1203 and Si02 when Li20 is kept in excess amount. When the molar percent of A1203: 1.120: S102 is from 5.4:22.5:68.3 to 7.4:20.5:68.3, the main crystal phases are petalite and LiAlSi308, with Li2SiO3 as a minor phase (FIG. 2A).
[157] Without wishing to be bound by any theory, based on the XRD pattern, LiAlSi308 is believed to be the solid solution of 8-spodumene due to similar peak positions. When the amount of A1203 is more than 7.4 mol%, the XRD shows the only presence of the 6-spodumene solid solution, as the petalite phase does not appear in the XRD pattern (FIG. 2B). Again, without wishing to be bound by any theory, it was hypothesized that L1A1S1308 is more preferable to crystalize than petalite (LiAlSiaOio), as the ratio of LiA102:Si02 is higher in LiAlSi308.
[158] It was also found that when A1203 is lower than 5.4 mol%, the crystal peak at 281,-38.4 becomes intensive (FIG. 2B). This peak is several times higher than others when the amount of A1203 is decreases to 3.4 mol%. Again, without wishing to be bound by any theory, this intensive peak (the plane (002) of Li2SiO3) is believed to be due to the anisotropic growth of lithium metasilicate crystals in glass-ceramics. When the amount of 6102 is too high compared with A1203, the crystal of 6102 can be present in the XRD pattern (FIG. 2B). Further, without wishing to be bound by any theory, it was found that the nucleation and crystal growth temperatures do not influence the types of crystal phases but influence the ratios of different crystals. The peak of the 13-spodumene solid solution was found to be more intensive, while the lithium metasilicate peak has disappeared at high temperatures.
059] As the crystal growth rate of transparent glass-ceramics is far less than the maximum growth rate, the crystalline to amorphous ratio continuously increases with increasing crystal growth temperature. This ratio can also be influenced by the amount of P205, B203, and Zr02. Again, without wishing to be bound by any theory, it is assumed that large Zr atoms increase the activation barrier, and thus, leading to the decrease of the frequency of successful jumps of atoms from liquid to crystals.
As a result, the crystalline to amorphous ratio largely decreases with more amount of Zr02. P205, as the nucleation agent, can decrease the nucleation temperature and increase the nucleation rate, and thus, resulting in an increase of crystalline to amorphous ratio. B203 has less influence on the ratio than Zr02 and P205. But high amount of B203 can lead to a decrease in the viscosity at crystal growth temperature, which slightly decreasing the activation barrier for the movement of atoms from liquid to crystals, and thus, causing the increase of crystalline to amorphous ratio.
DSC pattern and viscosity [160] Variations in glass transition temperature, melting point (TO, and crystallization temperature were investigated as a function of Li20 and A1203 amounts (FIG.3A-B). It was found that Tg linearly increases with an increasing amount of A1203 and a decreasing amount of Li20 (F1G.3B). It was found that Tg is 484 C for sample 12 with 3.4 mol% A1203 and 24.5 mol% Li20, increasing around 60 C for sample 13 with 11.4 mol% A1203 and 16.5 mol% Li20. It was further found that Tm decreases with an increasing amount of A1203 and a decreasing amount of Li20.
[161] Without wishing to be bound by any theory, the crystallization peak around 750 C is believed to be the peak of f3-spodumene solid solution, according to the phase diagram of LiA102-Si02 (FIG.4). The depth of this peak decreases with a decreasing amount of A1203, indicating that the 13-spodumene solid solution is less preferable in the low concentration of A1203. It was further found that in sample LAS12 with 3.4 mol% A1203, the negative peak at 723 C appears, which can possibly correspond to the melting point of Li2SiO3. Analysis of this sample also has shown the appearance of another crystallization peak around 860 C. Which wishing to be bound by any theory, this peak was attributed to 8-spodumene based on the phase diagram. No peaks of petalite were observed in the DSC pattern. Again, without wishing to be bound by any theory, it was hypothesized that such phenomena are due to the possible slow growth of petalite, compared with the Cimin heating rate in DSC. Again, without wishing to be bound by any theory, it was further hypothesized that this slow growth is responsible for the glass-ceramics samples staying transparent while being in the furnace for hours.
(1621 The viscosity-temperature curves of LAS10 and LAS11, as shown in FIGS.
5A-B were also compared with standard soda lime silicate glass (SG 80(a)). It was found that both LAS10 and LAS11 crystallize around 950 C at a 20 K/min cooling rate. The viscosity of lithium aluminosilicate glass was found to be less than SG80 at high temperatures. The data of LAS11 was then fitted with the Mauro-Yue-Ellison-Gupta-Allan (MYEGA) equation, using -2.93 for logical.. 7.9 fitted in the MYEGA
equation is 451 C, which is 61 C lower than Tg from DSC. Without wishing to be bound by any theory, it was assumed that this error can be due to the limited range of viscosity data at high temperatures. Fragility (m), the parameter useful in understanding liquid dynamics and glass transition behavior, can also be predicted from the MYEGA equation. It was found that the fragility of LAS11 is 27.
Density of glass samples and glass-ceramics samples (163] The densities of the glass samples were measured and were found to be in the range from 2.38 to 2.47 g/cm3, mainly influenced by the amount of ZrO2.
FIG. 6 shows that the densities of glass increase with the amount of ZrO2, Multiple linear regression equation was used to predict the influence of different oxides to the densities of glass (Equation 4):
p(g/cm3)=2.37745+0.00027[A1203]+0.00003[1_120]+0.00078[13203]+0.00000[Na2 0]+0.02481[Zr02]+0.00000(P205) (4) where p is the density, 2.37745 g/cm3 is the predicted density of pure silicate glass from a multiple linear regression equation with a percent error of 8.1%
compared with experimental data (2.20 g/cm3). Again, without wishing to be bound by any theory, this percent error was assumed to be mainly due to the simplified linear model. R2of the fitting model was found to be 0.92, indicating that 92 percent of the variabilities can be explained by the linear regression of different oxides.
From the fitted data, the density of the glass samples is mainly increased with the amount of ZrO2.
[164] It was shown that the densities of the glass-ceramics sample are slightly higher than their mother glass. Without wishing to be bound by any theory, it was assumed that this is due to the crystals in glass-ceramics having ordered structure and less open space. However, it was also found that the densities of glass-ceramics are less than about 2% higher than the density of their mother glass.
Transmittances [165] FIG. 7 shows the transmittance of different glass-ceramics samples prepared herein. The first number in the glass-ceramics, as shown in FIG. 7, refers to the nucleation temperature and nucleation time, and the second one refers to the crystal growth temperature and crystal growth time. It was found that most of the samples, except for sample LAS 26, exhibited the average transmittances in the visible light region (390-700 nm) higher than about 80% (Table 2).
Table 2. The transmittance of exemplary glass-ceramics samples.
T,% LAS10 LAS11 LAS24 LAS26 Ave. Trans. at 390 81.3 83.0 87.7 38.4 nm-700nm Trans. at 550 nm 82.6 84.5 88.2 40.9 Trans. at 400 nm 72.1 72.3 86.3 72.5 [166] It was further found that most of the investigated samples were transparent at low crystal growth temperature and tended to become translucent and opaque at a higher crystal growth temperature. Further, it was found that the samples containing a high amount of lithium metasilicate tended to be translucent or opaque at the low crystal growth temperature. Without wishing to be bound by any theory, it was assumed that transparency of the glass-ceramic compositions correlates with the anisotropic growth of lithium metasilicate, corresponding to the intensive peak in the XRD pattern.
[167] Further, samples containing a high amount of 8-spodumene solid solution were found to be transparent at the high crystal growth temperature. It was found, as shown in the DSC pattern, while 8-spodumene crystallizes at a higher temperature, compared to petalite and lithium metasilicate crystallization, the 8-spodumene crystals are smaller than petalite and lithium metasilicate crystals at the same crystal growth temperature.
Microstructure [168] FIGS. 8A-8C show the secondary electron images of the microstructure of opaque, translucent, and transparent LAS glass-ceramics from SEM. Due to the different chemical durability of crystals and glass to hydrofluoric acid, crystals are observed under the electron microscope. It shows that the crystal sizes increase with crystal growth temperature and exposure time. The crystal sizes of transparent glass ceramics are between 20 and 40 nm, which were measured directly under SEM.
Some small pits were observed on the surface of crystals due to the etching of hydrofluoric acid through the dislocations of crystals.
Vickers hardness and crack resistance [169] Indentation hardness and toughness of the exemplary samples disclosed herein are shown in Table 3. PPG, a standard soda lime silicate glass with 74 mol%
SiO2, 13.3 mol% Na2O, 8.3 mol% CaO, 0.06 mol% A1203 and 3.7 mol% MgO [43], were measured under the same condition. Indentation hardness of glass-ceramics samples, increasing with higher crystal growth temperature, was far higher than that of PPG. The indentation toughness of glass-ceramics samples was higher than that of soda-lime silicate glass (0.75 MPa-m12) and Pyrex (0.70 MPa=m1/2). Samples with a higher amount of Al2O3 were found to have higher indentation hardness and toughness.
[170] FIGS. 9A-B show the crack probabilities of glass-ceramics samples with different loads of indenters, compared with that of PPG. R2 of the Weibull distribution on different samples was greater than 0.87. The average crack resistance of the samples was found to be 0.56 kgf, or four times higher than that of PPG.
Without wishing to be bound by any theory, it was assumed that this high crack resistance is the result of the ceramming process. The interlocking microstructure created from crystal grains in glass-ceramics can promote crack bridging and deflection and thus, lead to an increase in crack resistance.
Thermal expansion coefficients [171] FIG. 10 shows the linear thermal expansion coefficients (GTE) obtained from TMA in the range from 25 C to 300 C for both IASI 0 and LAS11 glass and glass-ceramics The thermal expansion coefficients of glass-ceramics were found to be in the range of 40-90x10-7/ C, significantly higher than that of SiO2 glass (5.5x 1 0.7 / C). GTE of glass-ceramics was found to be lower than the corresponding glass, indicating that GTE of petalite and 8-spodumene crystals are lower than the glass matrix. GTE was higher in samples with a higher amount of Li2O.
[172] The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) "means for or "step for, respectively.
[173] In view of the described processes and compositions, hereinbelow are described certain more particularly described aspects of the inventions. These particularly recited aspects should not, however, be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the "particular" aspects are somehow limited in some way other than the inherent meanings of the language and formulas literally used therein.
Table 3. Indentation hardness and toughness of LAS glass-ceramics Sample Glass 58045904 58046104 58046304 Indentation 5.92 0.34 GPa 7.20 0.15 GPa 7.19 0.16 GPa 7.64 0.34 GPa Hardness Indentation 0.9510.02 0.9710.04 0.91-10.04 0.8910.05 Toughness MPa=M1/2 MPa= M1/2 MPa=m1/2 mpa.m1/2 Sample IASI LAS10 LAS10 LAS10 580.4 730 4 580 4 750 4 580 4 770_4 5804 790_4 Indentation 7.7710.26 GPa 7.7210.20 GPa 7.7010.18 GPa 7.9010.25 GPa Hardness Indentation 1.05 0.04 1.19 0.09 1.20 -0.03 1.28 0.07 Toughness MPa=M1/2 MPa=m1/2 MPa=M1/2 MPa=m1/2 Sample LAS11 LAS11 LAS11 LAS11 Glass 580_4 590_4 580_4 610_4 580_4 6304 Indentation 6.03 0.17 GPa 6.30 0.08 GPa 7.96 0.13 GPa 7.80 0.50 GPa Hardness Indentation 0.98-10.02 1.13-10.05 0.88-10.02 0.9110.13 Toughness MPa.m1/2 MPa.m112 NAPa=m1/2 MPa=m112 Sample LAS11 LAS11 LAS11 Soda-lime 5804 730_4 580_4 750_4 580_4 770_4 silicate glass(PPG) Indentation 7.81-10.28 GPa 7.7910.19 GPa 7.81-10.28 GPa 5.35-10.07 GPa Hardness Indentation 1.08 0.02 1.36-10.06 1.23-10.04 0.75-10.01 Toughness MPa-M/12 MPa-li1/12 mpa.m1/2 mpa.m1/2 ASPECTS:
[174] Aspect 1: A glass-ceramic composition comprising: from about 2 mol% to about 20 mol% of A1203. from about 2 mol% to about 45 mol% of Li20; and from about 48 mol% to about 80 mol% of Si02: having a p-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase.
[175] Aspect 2: The glass-ceramic composition of Aspect 1, wherein A1203 is present from about 5 mol% to about 7.5 mol %, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase and from about 20 to about 80% of the petalite phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
[176] Aspect 3: The glass-ceramic composition of Aspect 2, wherein Li20 is present from about 20 mo10/0 to about 25 mol%.
[177] Aspect 4: The glass-ceramic composition of Aspect 1, wherein A1203 is present from about 7 mol% to about 12 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the p-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
[178] Aspect 5: The glass-ceramic composition of any one of Aspects of 1-4, wherein the lithium silicate crystalline phase comprises a lithium metasilicate crystalline phase.
[179] Aspect 6: The glass-ceramic composition of any one of Aspects 1-5, further comprising from 0 mol% to about 8 mol% of B203, from 0 mol% to about 8 mol% of Zr02, from 0 mol% to about 5 mol% of P205, and from 0 mol% to about 5 mo10/0 of Na20.
[180] Aspect 7: The glass-ceramic composition of any one of Aspects 1-6, wherein the composition exhibits density from about 2.00 g/cm3 to about 2.6 g/cm3.
[181] Aspect 8: The glass-ceramic composition of any one of Aspects 1-7, exhibiting an average transmittance greater than about 80% over a wavelength range from about 390 nm to about 700 nm as measured for a sample prepared from the composition and having a thickness of about 2.00 mm.
[182] Aspect 9: The glass-ceramic composition of any one of Aspects 1-7, exhibiting an average transmittance between 20% and 80% over a wavelength range from about 390 nm to about 700 nm as measured for a sample prepared from the composition and having a thickness of about 2.00 mm.
[183] Aspect 10: The glass-ceramic composition of any one of Aspects 1-7, exhibiting an average transmittance lower than 20% over a wavelength range from about 390 nm to about 700 nm as measured for a sample prepared from the composition and having a thickness of about 2.00 mm.
[184] Aspect 11: The glass-ceramic composition of Aspect 8, comprising a plurality of crystal grains, wherein the median size of a crystal grain is from about 20 to about 80 nm.
[185] Aspect 12: The glass-ceramic composition of Aspect 9, comprising a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 80 nm to about 500 nm.
[186] Aspect 13: The glass-ceramic composition of Aspect 10, comprising a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 500 nm.
[187] Aspect 14: The glass-ceramic composition of any one of Aspects 1-13, exhibiting Vickers hardness equal to or greater than about 6.0 GPa.
[188] Aspect 15:The glass-ceramic composition of any one of Aspects 1-14, exhibiting Vickers hardness of at least about 5% greater than Vickers hardness of a standard soda lime silicate glass.
[189] Aspect 16: The glass-ceramic composition of any one of Aspects 1-15, exhibiting a crack-resistance greater than about 0.2 kgf.
[190] Aspect 17: The glass-ceramic composition of any one of Aspects 1-16, exhibiting a crack-resistance greater than about 0.4 kgf.
[191] Aspect 18: The glass-ceramic composition of any one of Aspects 1-17, exhibiting a crack-resistance that at least 4 times higher than a crack-resistance of a standard soda lime silicate glass.
[192] Aspect 19: The glass-ceramic composition of any one of Aspects 1-18 exhibiting a thermal expansion coefficient from about 40x107 to about 90x107 /
C.
[193] Aspect 20: The glass-ceramic composition of any one of Aspects 1-19, wherein the composition exhibits a glass transition temperature (Tg) from about 450 C to about 600 C.
[194] Aspect 21: The glass-ceramic composition of any one of Aspects 1-20, wherein the composition further comprises one or more of fining agents selected from Ce02, Sn02, Fe2O3. As203, Sb203, Mn02, or a combination thereof, and wherein the one or more fining agents are present in a total amount equal to or less than about 1 mol [195] Aspect 22: The glass-ceramic composition of any one of Aspects 1-21, further comprising one or more of coloring components selected from transition metal oxides and/or rare earth metal oxide, and wherein the one or more coloring components are present in a total amount equal to or less than about 1 mol%.
[196] Aspect 23: The glass-ceramic composition of any one of Aspects 1-22, further comprising a decolorizing agent comprising sodium sulphate, selenium compounds, erbium oxide, cerium oxide, cobalt oxide, manganese oxide, or any combination thereof.
[197] Aspect 24: The glass-ceramic composition of any one of Aspects 1-23, wherein the composition is ion-exchangeable.
[198] Aspect 25: A glass-ceramic composition comprising: Al2O3 present from about 2 mol% to about 20 mol%, SiO2 present from about 48 mol% to about 80 mol%; R'20 present from greater than 0 mol% to about 45 mol%, and wherein R'20 comprises Li2O. Na2O, K20, Ag2O, Cu2O, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase.
[199] Aspect 26: The glass-ceramic composition of Aspect 25, wherein when R'20 comprises 1..i20, the composition comprises a minor crystalline phase comprising a lithium silicate phase.
[200] Aspect 27: The glass-ceramic composition of Aspect 25 or 26, wherein Al2O3 is present from about 5 mol% to about 7.5 mol %, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of thef3-spodumene phase and from about 20 to about 80% of the petalite phase.
[201] Aspect 28: The glass-ceramic composition of Aspect 26, wherein A1203 is present from about 5 mol% to about 7.5 mol A) and Li2O is present from 20 mol% to about 25 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase and from about 20 to about 80% of the petalite phase, and a minor phase comprises up to 10 mol%
of the lithium silicate phase.
[202] Aspect 29: The glass-ceramic composition of Aspect 25 or 26, wherein A1203 is present from about 7 mol% to about 12 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the p-spodumene phase.
[203] Aspect 30: The glass-ceramic composition of Aspect 26, wherein A1203 is present from about 7 mol% to about 12 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the p-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
[204] Aspect 31: The glass-ceramic composition of any one of Aspects 25-30, wherein the composition further comprises: B203 present from 0 mol% to about 8 mol%, ZrO2 from 0 mol% to about 8 mol%, and P205 from 0 mol% to about 5 mol%.
(2051 Aspect 32: The glass-ceramic composition of any one of Aspects 25-31, wherein the composition is transparent, translucent, or opaque.
[206] Aspect 33: The glass-ceramic composition of any one of Aspects 25-32, comprising a compressive stress layer.
[207] Aspect 34: The glass-ceramic composition of any one of Aspects 25-33, wherein the composition exhibits density from about 2.00 g/cm3 to about 2.6 g/cm3.
[208] Aspect 35: The glass-ceramic composition of any one of Aspects 32-34, wherein the composition is transparent and comprises a plurality of crystal grains, wherein the median size of a crystal grain is from about 20 to about 80 nm.
[209] Aspect 36: The glass-ceramic composition of any one of Aspects 32-34, wherein the composition is translucent and comprises a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 80 nm to about 500 nm.
[210] Aspect 37: The glass-ceramic composition of any one of Aspects 32-34, wherein the composition is opaque and comprises a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 500 nm.
[211] Aspect 38: The glass-ceramic composition of any one of Aspects 25-37.
exhibiting Vickers hardness equal to or greater than about 6.0 GPa.
[212] Aspect 39: The glass-ceramic composition of any one of Aspects 25-38, exhibiting Vickers hardness of at least about 5% greater than Vickers hardness of a standard soda lime silicate glass.
[213] Aspect 40: The glass-ceramic composition of any one of Aspects 25-39, exhibiting a crack-resistance greater than about 0.2 kgf.
[214] Aspect 41: The glass-ceramic composition of any one of Aspects 25-40, exhibiting a crack-resistance greater than about 0.4 kgf.
[215] Aspect 42: The glass-ceramic composition of any one of Aspects 25-41, exhibiting a crack-resistance that at least 4 times higher than a crack-resistance of a standard soda lime silicate glass.
[216] Aspect 43: The glass-ceramic composition of any one of Aspects 25-42, exhibiting a thermal expansion coefficient from about 40x107 to about 90x10-71 C.
[217] Aspect 44: The glass-ceramic composition of any one of Aspects 25-43, wherein the composition exhibits a glass transition temperature (Tg) from about 450 C to about 600 (C.
[218] Aspect 45: The glass-ceramic composition of any one of Aspects 25-44, wherein the composition further comprises one or more fining agents selected from Ce02, Sn02, Fe2O3, A5203, Sb203, Mn02, or a combination thereof, and wherein the one or more fining agents are present in a total amount equal to or less than about 1 mol %.
[219] Aspect 46: The glass-ceramic composition of any one of Aspects 25-45, wherein the composition further comprises a decolorizing agent comprising sodium sulphate, selenium compounds, erbium oxide, cerium oxide, cobalt oxide, manganese oxide, or any combination thereof.
[220] Aspect 47: The glass-ceramic composition of any one of Aspects 25-46, further comprising one or more coloring components selected from transition metal oxides and/or rare earth metal oxide, and wherein the one or more coloring components are present in a total amount equal to or less than about 1 mol0/0.
[221] Aspect 48: The glass-ceramic composition of any one of Aspects 25-47, wherein Ag2O, and/or Cu2O, and/or CuO is present and wherein the glass-ceramic composition exhibits antimicrobial, antiviral, antibacterial, and/or antifungal properties.
[222] Aspect 49: A glass-ceramic article comprising the composition of any one of Aspects 1-48.
[223] Aspect 50: A glass-ceramic article comprising the composition of any one of Aspects 33-48, wherein the compressive stress layer extends from a surface of the article to a depth of the compressive stress layer, and wherein the depth is from about 1 pm to about 100 pm.
[224] Aspect 51: A glass-ceramic article comprising the composition of any one of Aspects 33-48, wherein the compressive stress layer extends from a surface of the article to a depth of the compressive stress layer, and wherein the depth is up to about 25 % of a thickness of the glass-ceramic article.
[225] Aspect 52: A glass-ceramic article comprising: from about 2 mol% to about 20 mol% of A1203; from about 2 mol% to about 45 mol% of Li20, and from about mol% to about 80 mol% of SiO2; having a 13-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase.
[226] Aspect 53: A glass-ceramic article comprising: A1203 present from about mol% to about 20 mol%; SiO2 present from about 48 mol% to about 80 mol%; and R'20 present from greater than 0 mol% to about 45 mol%, wherein R'20 comprises Li20, Na20, 1(20, Ag20, Cu20, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising al3-spodumene phase, and optionally, a petalite phase.
[227] Aspect 54: The article of any one of Aspects 49-53, wherein the article comprises a hollowware, tableware, container, plate, sheet, float/flat sheet, cookware, powder, fiber, cones, spheres, blades, or any combination thereof.
[228] Aspect 55: The article of any one of Aspects 49-54, wherein the article is formed by a float/flat glass press process, a press-and-blow process, a blow-and-blow process, or any combination thereof.
[229] Aspect 56: A tableware comprising the composition of any one of Aspects 48.
[230] Aspect 57: The tableware of Aspect 56. wherein the tableware is formed by a glass press process, a press-and-blow process, and/or a blow-and-blow process.
[231] Aspect 58: A hollowware comprising the composition of any one of Aspects 1-48.
(.232] Aspect 59: The hollowware of Aspect 57, wherein the hollowware is formed by a glass press process, a press-and-blow process, and/or a blow-and-blow process.
[233] Aspect 60: A powder comprising the composition of any one of Aspects 1-48.
[234] Aspect 61: A cookware comprising the composition of any one of Aspects 1-48.
(.235] Aspect 62: The cookware of Aspect 61, wherein the cookware is formed by a glass press process, a press-and-blow process, and/or a blow-and-blow process.
[236] Aspect 63: A fiber comprising the composition of any one of Aspects 1-48.
(.237] Aspect 64: The fiber of Aspect 63, wherein the fiber is formed by a continuous or discontinuous fiber drawing or spinning process.
[238] Aspect 65: A float or flat glass press product comprising the composition of any one of Aspects 1-48.
[239] Aspect 66: A press-and-blow process product comprising the composition of any one of Aspects 1-48.
[240] Aspect 67: A blow-and-blow process product comprising the composition of any one of Aspects 1-48.
[241] Aspect 68: A method comprising: forming a mixture comprising: a) from about 2 mol% to about 20 mol% of A1203. from about 2 mol% to about 45 mol% of Li2O; and from about 48 mol% to about 80 mol% of SiO2; b) forming a homogeneous composition; and c) ceramming the homogeneous composition to form a glass-ceramic composition.
(242] Aspect 69: The method of Aspect 68, wherein the mixture further comprises from 0 mol% to about 8 mol% of Zr02, or from 0 mol% to about 5 mol% of P205, or a combination thereof.
[243] Aspect 70: The method of Aspect 68 or 69, wherein the step of forming the homogenous composition comprises melting the mixture in a furnace at a temperature from about 1,300 C to about 1,700 C for a first predetermined time.
[244] Aspect 71: The method of Aspect 70, further comprising a step of annealing at a temperature from about 450 C to about 700"C.
[245] Aspect 72: The method of any one of Aspects 68-71, wherein the step of ceramming comprises heating the homogenous composition at a nucleation temperature for a second predetermined time.
[246] Aspect 73: The method of Aspect 72, wherein the nucleation temperature is from about 450 C to about 650 "C.
[247] Aspect 74: The method of Aspect 71 or 72, wherein the step of ceramming further comprises a step of heating the composition to a crystallization temperature at a rate from about 5 C/min to about 15 C/min and keeping the composition at the crystallization temperature for a third predetermined time.
[248] Aspect 75: The method of Aspect 74, wherein the crystallization temperature is from about 580 C to about 800 C.
[249] Aspect 76: The method of any one of Aspects 74-75, wherein the first, the second, and/or the third predetermined times are from about 3 to 5 hours.
[250] Aspect 77: The method of any one of Aspects 72-76, wherein P205 is a nucleation agent.
[251] Aspect 78: The method of any one of Aspects 74-77, wherein Zr02 is a crystal size growth-limiting agent.
[252] Aspect 79: The method of any one of Aspects 68-78, wherein the glass-ceramic composition comprises a 13-spodumene phase, optionally petalite phase, and a lithium silicate crystalline phase.
[253] Aspect 80: The method of Aspect 79, wherein Al2O3 is present from about mol% to about 7.5 mol %, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase and from about 20 to about 80% of the petalite phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
[254] Aspect 81: The method of Aspect 80, wherein Li2O is present in the composition from about 20 mol% to about 25 mol%.
[255] Aspect 82: The method of Aspect 81, wherein Al2O3 is present from about mol% to about 12 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of theii-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
[256] Aspect 83: The method of any one of Aspects 80-82, wherein the lithium silicate crystalline phase comprises a lithium metasilicate crystalline phase.
[257] Aspect 84: The method of any one of claims 68-83, wherein the mixture further comprises from 0 mol% to about 8 mol% of B203, and from 0 mol% to about 8 mol% of Na2O.
[258] Aspect 85: The method of any one of Aspects 68-84, further comprising a step of ion exchange treatment comprising exposure to a salt bath, spray, paste, a vapor-assisted ion exchange, a plasma-assisted ion exchange, or any combination thereof.
[259] Aspect 86: The method of Aspect 85, wherein the ion exchange treatment is electrically accelerated.
[260] Aspect 87: The method of Aspect 85 or 86, wherein the step of ion-exchange treatment comprises placing the glass-ceramic composition into a molten salt bath comprising sodium, potassium, silver, or copper (1) ions, or a combination thereof at conditions effective to provide an ion-exchanged glass-ceramic composition.
[261] Aspect 88: The method of Aspect 87, wherein the ion-exchanged glass-ceramic composition comprises: Al2O3 present from about 2 mol% to about 20 mol%;
SiO2 present from about 48 mol% to about 80 mol%; R'20 present from greater than 0 mol% to about 45 mol%; and wherein R'20 comprises L120, Na2O, K20, Ag2O, Cu2O, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase.
[262] Aspect 89: The method of Aspect 87 or 88, wherein the conditions effective to provide the ion-exchanged glass-ceramic composition comprise exposure of the glass-ceramic composition to a molten salt at a temperature from about 380 C
to about 500 C for a time period from about 4 hours to about 20 hours.
[263] Aspect 90: The method of any one of Aspects 87-89, wherein the ion-exchanged glass-ceramic composition comprises a compressive stress layer.
[264] Aspect 91: The method of any one of Aspects 68-90, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit density from about 2.00 g/cm3 to about 2.6 g/cm3.
[265] Aspect 92: The method of any one of Aspects 68-91 wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit an average transmittance greater than about 80% over a wavelength range from about 390 nm to about 700 nm for a sample formed from the glass-ceramic and/or the ion-exchanged glass-ceramic composition and having a thickness of about 2.00 mm.
[266] Aspect 93: The method of any one of Aspects 68-92, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit an average transmittance between 20% and 80% over a wavelength range from about 390 nm to about 700 nm as measured for a sample formed from the glass-ceramic and/or the ion-exchanged glass-ceramic composition and having a thickness of about 2.00 mm.
[267] Aspect 94: The method of any one of Aspects 68-93, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit an average transmittance lower than 20% over a wavelength range from about 390 nm to about 700 nm as measured for a sample formed from the glass-ceramic and/or the ion-exchanged glass-ceramic composition and having a thickness of about 2.00 mm.
[268] Aspect 95: The method of Aspect 94, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition comprise a plurality of crystal grains, wherein a size of a crystal grain is from about 20 to about 80 nm.
[269] Aspect 96: The method of Aspect 95, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition comprises a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 80 nm to about 500 nm.
[270] Aspect 97: The method of Aspect 96, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition comprise a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 500 nm.
(271] Aspect 98: The method of any one of Aspects 68-97, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit Vickers hardness equal to or greater than about 6.0 GPa.
[272] Aspect 99: The method of any one of Aspects 68-98, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit Vickers hardness of at least about 5% greater than Vickers hardness of a composition comprising a standard soda lime silicate glass.
[273] Aspect 100: The method of any one of Aspects 68-99, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit a crack-resistance greater than about 0.2 kgf.
[274] Aspect 101: The method of any one of Aspects 68-100, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit a crack-resistance greater than 0.4 kgf.
[275] Aspect 102: The method of any one of Aspects 68-101, wherein the glass-ceramic composition exhibits a crack-resistance that at least 4 times higher than a crack -resistance of a composition comprising a standard soda lime silicate glass.
[276] Aspect103: The method of any one of Aspects 68-102, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit a thermal expansion coefficient from about 40x107 to about 90x10-7 [277j Aspect 104: The method of any one of Aspects 68-103, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit a glass transition temperature Tg from about 450 C to about 600 C.
[278] Aspect 105: The method of any one of Aspects 68-104 further comprising a step of forming a glass-ceramic article.
(279] Aspect 106: The method of Aspect 105, wherein the step of forming the glass-ceramic articles comprises a float or flat press process, a press-and-blow process, a blow-and-blow process, or any combination thereof.
[280] Aspect 107: The method of Aspect 105 or 106, wherein the glass-ceramic article comprises the ion-exchange composition and wherein the compressive stress layer extends from a surface of the article to a depth of the compressive stress layer, wherein the depth is from about 1 pm to about 100 pm.
[281] Aspect 108: The method of any one of Aspects 105-107, wherein the glass-ceramic article comprises the ion-exchange composition and wherein the compressive stress layer extends from a surface of the article to a depth of the compressive stress layer, and wherein the depth is up to about 25 % of a thickness of the glass-ceramic article.
[282] Aspect 109: The method of any one of Aspects 105-108, wherein the article comprises a hollowware, tableware, container, plate, sheet, float/flat sheet, cookware, powder, fiber, cones, spheres. blades, or any combination thereof.
[283] Aspect 110: A method of forming an article comprising forming a composition of any one of Aspects 1-48; and then forming the article, wherein the article comprises a hollowware, tableware, container, plate, sheet, float/fiat sheet, cookware, powder, fiber, cones, spheres, blades, or any combination thereof.
[284] Aspect 111: The method of Aspect 110, wherein the step of forming comprises a float/flat press process, a press-and-blow process, a blow-and-blow process, or any combination thereof.
[285] Aspect 112: The method of Aspect 110 or 111, wherein the step of forming the composition comprises the method of any one of Aspects 68-104.
REFERENCES
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(2019) 277-280.
[3] S. Wen, Y. Wang, B. Lan, W. Zhang, Z. Shi, S. Lv, Y. Zhao, J. Qiu & S.
Zhou, Pressureless crystallization of glass for transparent nanoceramics, Adv. Sci.
6 (17) (2019) 1901096.
[4] W. Noland, & G. H. Beall, Glass-ceramic technology, John Wiley & Sons (2019).
[5] H. Bach ed., Low thermal expansion glass ceramics, Springer Science &
Business Media (2013).
[6] M. Krishna Murthy, & F. A. Hummel, Phase equilibria in the system lithium metasilicate¨p-eucryptite, J. Am, Ceram. Soc. 37 (1) (1954) 14-17.
[7] G. H. Beall, Q. Fu, & C. M. Smith, U.S. Patent No. 9,809,488. Washington, DC:
U.S. Patent and Trademark Office (2017).
[8] G. H. Beall, & L. R. Pinckney, Nanophase glass-ceramics, J. Am. Ceram.
Soc. 82 (1) (1999) 5-16.
[9] C T. Li, The crystal structure of LiAlSi206 III (high-quartz solid solution), Z.
Kristallogr.-Cryst. Mater. 127 (1-6) (1968) 327-348.
[10] G. H. Beall, and D. A. Duke, Transparent glass-ceramics, J. Mater. Sci. 4 (4) (1969) 340-352.
[103] In still further aspects, the compressive stress layer can exhibit a compressive stress of at least about 10 MPa, at least about 20MPa, at least about 50 MPa, at least about 80 MPa, at least about 100 MPa, at least about 120 MPa, at least about 150 MPa, at least about 180 MPa, at least about 200 MPa, at least about 210 MPa, or at least about 250 MPa.
[104] In still further aspects, the articles disclosed herein exhibit a ring-on-ring strength of at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 35%, or at least 40%, or at least 45%, or at least 50% higher than that of standard soda lime silicate glass tested under similar conditions.
(105] In yet further aspects, the articles can be substantially transparent.
While in other aspects, the articles can be substantially translucent. While still in other aspects, the articles can be substantially opaque. In still further aspects, the articles can comprise compositions comprising a coloring component. In such exemplary aspects, the articles can have a color.
(106] In still further aspects, the articles can comprise any known in the art articles that require the disclosed herein mechanical and optical properties. Yet in other aspects, the articles disclosed herein can comprise a hollowware, tableware, container, plate, sheet (including sheet prepared via the float process), cookware, powder, fiber, cones, spheres, blades, or any combination thereof. In still further aspects, the articles disclosed herein can be formed by any process. For example, the articles can be formed by a float or flat press process, a press-and-blow process, a blow-and-blow process, or any combination thereof. While in still further aspects, disclosed herein articles can also be used in a variety of electronic devices or portable computing devices, light diffusers, automotive, appliances, medical industry, food industry, and even architectural applications. In still further aspects, the articles disclosed herein can have known in the art shape or configuration.
[107] Also disclosed herein is a tableware comprising any of the disclosed above glass-ceramic compositions. In certain aspects and without limitations, the tableware can comprise a blown and/or pressed product. In still further exemplary aspects, the tableware can be formed by a press process, a press-and-blow process, a blow-and-blow process, or any combination thereof. In yet other aspects, disclosed herein is a hollowware comprising any of the disclosed above glass-ceramic compositions.
In certain aspects and without limitations, the hollowware can be formed by a press-and-blow process, a blow-and-blow process, or a combination thereof. Also disclosed herein is a cookware comprising any of the disclosed above glass-ceramic compositions. In still further aspects, disclosed herein is a powder comprising any of the disclosed above glass-ceramic compositions. In certain aspects and without limitations, the cookware can be formed by a press process, a press-and-blow process, a blow-and-blow process, or any combination thereof While in other aspects, disclosed herein is a fiber comprising any of the disclosed above glass-ceramic compositions. In certain aspects and without limitations, the fiber can comprise a continuous or discontinuous fiber product or a fiberglass reinforced composite.
METHODS
[108] Also disclosed herein are methods of making the disclosed compositions and the disclosed articles. In certain aspects, disclosed herein is a method comprising: a) forming a mixture comprising from about 2 mol% to about 20 mol%
of A1203, from about 2 mol% to about 45 mol% of Li20; and from about 48 mol% to about 80 mol% of SiO2; b) forming a homogeneous composition; and c) ceramming the homogeneous composition to form a glass-ceramic composition.
[109] Yet in other aspects, disclosed herein is a method comprising: a) forming a mixture comprising from about 3 mol% to about 12 mol% of A1203, from about 13 mol% to about 45 mol% of Li20; and from about 48 mol% to about 75 mol% of Si02;
b) forming a homogeneous composition; and c) ceramming the homogeneous composition to form a glass-ceramic composition.
[110] It is understood that A1203, Li20, and Si0.2 can be present in any amounts as disclosed in the above-described compositions.
[111] In still further aspects, the mixture formed by the methods disclosed herein can further comprise from 0 mol% to about 8 mol% of Zr02, or from 0 mol% to about mol% of P205, or a combination thereof. While in other aspects, the mixture formed by the methods disclosed herein can further comprise from 0 mol% to about 3 mol%
of Z102, or from 0 mol% to about 3 mol% of P205, or a combination thereof. It is understood that both Zr02 and P205 can be present in any amounts as disclosed in the above-described compositions.
[112] In yet further aspects, the step of forming the homogenous composition comprises melting the mixture in a furnace at a temperature from about 1300 CC
to about 1,700 c=C for a first predetermined time. In such temperature the temperature in the furnace can be any temperature in a range from about 1,300 C to about 1,700 C, including exemplary values of about 1,310 C, about 1,320 C, about 1,330 C, about 1,340 C, about 1350 C, about 1,360 C, about 1,370 C, about 1,380 C, about 1,390 C, about 1,400 C, about 1,410 C, about 1,420 C, about 1,430 C, about 1,440 C, about 1,450 C, about 1,460 C, about 1,470 C, about 1,480 C, about 1,490 C, about 1,500 C, about 1,510 C, about 1,520 C, about 1,530 C, about 1,540 C, about 1,550 C, about 1,560 C, about 1,570 C, about 1,580 C, about 1,590 C, about 1,600 C, about 1,610 C, about 1,620 C, about 1,630 C, about 1,640 C, about 1,650 C, about 1,660 C, about 1,670 C, about 1,680 C, and about 1,690 C.
[113] In still further aspects, the methods disclosed herein can further comprise a step of annealing at a temperature from about 450 C to about 700 C, including exemplary values of about 460 C, about 470 C, about 480 C, about 490 C, about 500 CC, about 510 C, about 520 C, about 530 C, about 540 C, about 550 C, about 560 C, about 570 C, about 580 C, about 590 C, about 600 C, about CC, about 620 CC, about 630 C, about 640 C, about 650 C, about 660 C, about 670 C, about 680 C, and about 690 C.
[114] In yet further aspects, the step of ceramming comprises heating the homogenous composition at a nucleation temperature for a second predetermined time. In such exemplary aspects, the nucleation temperature is from 450 C to about 700 C, including exemplary values of about 460 C, about 470 CC, about 480 c about 490 C, about 500 C, about 510 C, about 520 C, about 530 C, about 540 C, about 550 C, about 560 C, about 570 C, about 580 C, about 590 C, about 600 CC, about 620 C, about 630 C, about 640 C, about 650 CC, about 660 C, about 670 cC, about 680 C, about 690 C.
[115] In still further aspects, in the methods disclosed herein, the step of ceramming further comprises a step of heating the composition to a crystallization temperature at a rate from about 5 C/min to about 15 C/min and keeping the composition at the crystallization temperature for a third predetermined time.
In such exemplary aspects, the heating is performed at a rate from about 5 C/min to about 15 C/min, including exemplary aspects, of about 6 C/min, about 7 C/min;
about 8 C/min, about 9 C/min, about 10 C/min, about 11 C/min, about 12 C/min, about 13 C/min, and about 14 C/min.
[116] In still further aspects, the crystallization temperature is from about 580 C to about 800 C, including exemplary values of about 590 C, about 600 C, about C, about 620 C, about 630 C, about 640 ''C, about 650 C, about 660 C, about 670 f'C, about 680 C, about 690 C, about 700 C, about 710 C, about 720 C, about 730 C, about 740 C, about 750 C, about 760 C, about 770 C, about C, and about 790 C.
[117] It is understood that one skilled in the art can adjust the nucleation and crystallization temperatures to accommodate the different glass compositions within the above-described range.
[118] In yet further aspects, the first predetermined time is from about 0.5 hours to about 20 hours, including exemplary values of about 1 hour, about 1.5 hours, about 2 hours, about 2.5 hours, about 3 hours, about 3.5 hours, about 4 hours, about 4.5 hours, about 5 hours, about 5.5 hours, about 6 hours, about 6.5 hours, about 7 hours, about 7.5 hours, about 8 hours, about 9.5 hours, about 10 hours, about 10.5 hours, about 11 hours, about 11.5 hours, about 12 hours, about 12.5 hours, about 13 hours, about 13.5 hours, about 14 hours, about 14.5 hours, about 15 hours, about 15.5 hours, about 16 hours, about 16.5 hours, about 17 hours, about 17.5 hours, about 18 hours. about 18.5 hours, about 19 hours, and about 19.5 hours.
[119] In yet further aspects, the first predetermined time is from about 3 hours to about 5 hours, including exemplary values of about 3.1 hours, about 3.2 hours, about 3.3 hours, about 3.4 hours, about 3.5 hours, about 3.6 hours, about 3.7 hours, about 3.8 hours, about 3.9 hours, about 4.0 hours, about 4.1 hours, about 4.2 hours, about 4.3 hours, about 4.4 hours, about 4.5 hours, about 4.6 hours, about 4.7 hours, about 4.8 hours, and about 4.9 hours.
[120] In yet further aspects, the second predetermined time is from about 0.5 hours to about 20 hours, including exemplary values of about 1 hour, about 1.5 hours, about 2 hours, about 2.5 hours, about 3 hours, about 3.5 hours, about 4 hours, about 4.5 hours, about 5 hours, about 5.5 hours, about 6 hours, about 6.5 hours, about 7 hours, about 7.5 hours, about 8 hours, about 9.5 hours, about hours, about 10.5 hours, about 11 hours, about 11.5 hours, about 12 hours, about 12.5 hours, about 13 hours, about 13.5 hours, about 14 hours, about 14.5 hours, about 15 hours, about 15.5 hours, about 16 hours, about 16.5 hours, about 17 hours, about 17.5 hours, about 18 hours, about 18.5 hours, about 19 hours, and about 19.5 hours.
[121] In yet further aspects, the second predetermined time is from about 3 hours to about 5 hours, including exemplary values of about 3.1 hours, about 3.2 hours, about 3.3 hours, about 3.4 hours, about 3.5 hours, about 3.6 hours, about 3.7 hours, about 3.8 hours, about 3.9 hours, about 4.0 hours, about 4.1 hours, about 4.2 hours, about 4.3 hours, about 4.4 hours, about 4.5 hours, about 4.6 hours, about 4.7 hours, about 4.8 hours, and about 4.9 hours.
[122] In yet further aspects, the third predetermined time is from about 0.5 hours to about 20 hours, including exemplary values of about 1 hour, about 1.5 hours, about 2 hours, about 2.5 hours, about 3 hours, about 3.5 hours, about 4 hours, about 4.5 hours, about 5 hours, about 5.5 hours, about 6 hours, about 6.5 hours, about 7 hours, about 7.5 hours, about 8 hours, about 9.5 hours, about 10 hours, about 10.5 hours, about 11 hours, about 11.5 hours, about 12 hours, about 12.5 hours, about 13 hours, about 13.5 hours, about 14 hours, about 14.5 hours, about 15 hours, about 15.5 hours, about 16 hours, about 16.5 hours, about 17 hours, about 17.5 hours, about 18 hours, about 18.5 hours, about 19 hours, and about 19.5 hours.
[123] In yet further aspects, the third predetermined time is from about 3 hours to about 5 hours, including exemplary values of about 3.1 hours, about 3.2 hours, about 3.3 hours, about 3.4 hours, about 3.5 hours, about 3.6 hours, about 3.7 hours, about 3.8 hours, about 3.9 hours, about 4.0 hours, about 4.1 hours, about 4.2 hours, about 4.3 hours, about 4.4 hours, about 4.5 hours, about 4.6 hours, about 4.7 hours, about 4.8 hours, and about 4.9 hours.
[124] In yet further aspects, the first, second, and/or third predetermined times can be the same or different.
[125] In certain aspects, in the methods disclosed herein, P205 can behave as a nucleation agent. As used herein, the term a "nucleation agent" refers to a component in the glass-ceramics (and/or the precursor glass composition and/or glass that includes such a composition) that serves as the starting point of the nuclei itself (i.e, is a discontinuity or defect in the homogenous or amorphous phase from which the crystal phase is generated), and does not require other components to promote nucleation. It is understood that in other exemplary aspects, also TiO2 and/or ZrO2 can also be used as the nucleation agents.
[126] While in other aspects, ZrO2 can be a crystal size growth- limiting agent.
[127] Also disclosed herein are aspects where the glass-ceramic compositions formed by the disclosed herein methods can comprise p-spodumene phase, optionally petalite phase, and a lithium silicate crystalline phase.
[128] In still further aspects, the glass-ceramic composition formed by the disclosed methods can comprise Al2O3 in an amount from about 5 mo10/0 to about 7.5 mol 0/0, including exemplary values of about 5.1 mol%, about 5.2 mol%, about 5.3 mol%, about 5.4 mol%, about 5.5 mol%, about 5.6 mol%, about 5.7 mol%, about 5.8 mol%, about 5.9 mol%, about 6.0 mol%, about 6.1 mol%, about 6.2 mol%, about 6.3 mol%, about 6.4 mol%, about 6.5 mol%, about 6.6 mol%, about 6.7 mol%, about 6.8 rriol /0, about 6.9 mol%. about 6.9 rnal%, about 7.0 mol%, about 7.1 mol%, about 7.2 mol%, about 7.3 mol%, and about 7.4 mol%. In such exemplary values, the glass-ceramic article comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase, including exemplary values of 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, and about '75% of the p-spodumene phase. In still further aspects, the major phase can comprise from about 20 to about 80% of the petalite phase 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, and about 75% of the p-spodumene phase. In still further aspects, such compositions can comprise a minor crystalline phase comprising up to about 10% of the lithium silicate phase, including exemplary values of about 0.01(%, about 0.05%, about 0.1%, about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 9.5, and about 9.99%.
[129] In yet further exemplary aspects, when Al2O3 is present from about 5 mol%
to about 7.5 mot 0/0, Li2O can be present from about 20 mol% to about 25 mol%, including exemplary values of about 21 mol%, about 21.5 mol%, about 22 mol%, about 22 5 mol%, about 23 mol%, about 23.5 mol%, about 24 molok, and about 24.5 mol%.
[130] In still further aspects, the glass-ceramic composition formed by the disclosed methods can comprise A1203 in an amount from about 7 mol% to about mol%, including exemplary values of about 7.1 mol%, about 7.2 mol%, about 7.3 mol%, about 7.4 mol%. about 7.5 mol%, about 7.6 mol%, about 7.7 mol%, about 7.8 mol%, about 7.9 mol%, about 8.0 mol%, about 8.1 mol%, about 8.2 mol%, about 8.3 mol%, about 8.4 mol%, about 8,5 mol%, about 8.6 mol%, about 8.7 mol%, about 8.8 mol%, about 8.9 moi%, about 9.0 mol%, about 9.1 mol%, about 9.2 mol%, about 9.3 mol%, and about 9.4 mol%, about 9.5 mol%, about 9.6 mol%, about 9.7 mol%, about 9.8 mol%, about 9.9 mol%, about 10.0 mol%, about 10.1 mol%, about 10.2 mol%, about 10.3 mol%, about 10.4 mol%, about 10.5 mol%, about 10.6 mol%, about 10.7 mol%, about 10.8 mol%, about 10.9 mol%, about 11.00 mol%, about 11.1 mol%, about 11.2 mol%, about 11.3 mol%, about 11.4 mol%, about 11.5 mol%, about 11.6 mol%, about 11.7 mol%, about 11.8 mol%, and about 11.9 mol%. In such exemplary aspects, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the 0-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase. In such aspects, the major crystalline phase can comprise from about 60% to about 90%
of the 0-spodumene phase, including exemplary values of about 65%, about 70%, about 75%, about 80%, and about 85% of the p-spodumene phase. While in other aspects, the minor crystalline phase comprising up to about 10% of the lithium silicate phase, including exemplary values of greater than 0%, about 0.01%, about 0.05%, about 0.1%, about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 9.5%,about 9.9%, and about 9.99%. In still further aspects, when the lithium silicate crystalline phase is present, it can comprise a lithium metasilicate crystalline phase.
[131] In still further aspects, the mixture formed by the disclosed herein compositions can further comprise from about from 0 mol% to about 8 mol% of 8203, and from 0 mol% to about 8 mol% of Na20. While in still further aspects, the mixture formed by the disclosed herein compositions can further comprise from about from 0 M01% to about 5 mol% of B203, and from 0 mol% to about 3 mol% of Na2O. It is understood that both 8203 and Na20 can be present in any amounts, as disclosed in the above-described compositions.
[132] In still further aspects, the methods disclosed herein can comprise a step of ion-exchange treatment comprising placing the glass-ceramic composition into a molten salt bath. In such aspects, the molten salt bath can comprise any ions that can be used for an ion-exchange of the glass-ceramic composition. In certain aspects, the molten bath can comprise sodium, potassium, silver, or copper (I) ions, or a combination thereof. In still other aspects, the ion-exchange treatment can be performed at conditions effective to provide an ion-exchanged glass-ceramic composition.
[133] In still further aspects, the molten bath can comprise any of the disclosed ions or their mixtures. In certain aspects, the conditions effective to provide the ion-exchanged glass-ceramic composition comprise exposure of the glass-ceramic composition to a molten salt at a temperature from about 380 C to about 500 including exemplary values of about 390 C, about 400 C, about 410 C, about C, about 430 C, about 440 C, about 450 C, about 460 C, about 470 C, about 480 C, and about 490 C and for a time period from about 4 hours to about 20 hours, including exemplary values of about 5 hours, about 6 hours, about 7 hours, about 8 hours, about 9 hours, about 10 hours, about 11 hours, about 12 hours, about 13 hours, about 14 hours, about 15 hours, about 16 hours, about 17 hours, about 18 hours, and about 19 hours.
[134] In some further exemplary and unlimiting aspects, the step of ion exchange treatment can be done after the step of ceramming.
351 It is further understood that in aspects disclosed herein, the step of ion-exchange treatment can comprise placing the disclosed herein composition in a first molten bath comprising one or more molten oxides and forming a first ion-exchanged composition. While in other aspects, the methods can further comprise placing the first-ion exchanged composition in a second bath comprising one or more molten oxide and forming a second ion-exchanged composition, and so on until the desired ion-exchanged composition is formed. It is understood that in these exemplary and unlimiting aspects, the first and the second molten bath compositions can comprise the same or different molten oxides In yet other aspects, the desired ion-exchanged composition can be formed in one step. In some exemplary aspects, the molten bath comprising potassium (K) ions (or silver (Ag) or copper (Cu) (I)) or Cu (II) can replace sodium (Na) ions or lithium (Li) ions in the glass-ceramic composition depending on the temperature conditions. In yet other exemplary aspects, the molten bath comprising sodium (Na) ions can further replace lithium (Li) ions in the glass-ceramic composition depending on the temperature conditions. In still further aspects, other alkali metal ions such as cesium or rubidium can also be present. In yet other exemplary and unlimiting aspects, the ion-exchange can also be done with divalent metal ions, such as calcium, barium, or magnesium, if desired. It is also understood that the molten baths can comprise any known in the art salts of the desired metal ions, for example, the salts can comprise nitrates, sulfates, halides, and the like.
[136] It is further understood that any known in the art mechanisms of the ion-exchange can be contemplated. In certain aspects, larger ions in the composition can be replaced with the smaller ions in the bath. Yet, in further aspects, the smaller ions the compositions are replaced with larger ions on the bath. Such ion-exchange processes can be controlled by tuning the temperature and exposure time.
(137] In yet further aspects, when the bath comprises silver or copper ions, the formed ion-exchanged compositions can exhibit antimicrobial, antibacterial, antifungal, or antiviral properties to the material.
[138] In still further aspects, the ion-exchanged glass-ceramic composition comprises: a) Al2O3 present from about 2 mol% to about 20 mol%; b) SiO2 present from about 48 mol% to about 80 mol%; R'20 present from greater than 0 mol% to about 45 inol%, and wherein R'20 comprises Li2O, Na2O, K20, Ag2O, Cu2O. CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase. While yet on other aspects, the ion-exchanged glass-ceramic composition comprises: a) Al2O3 present from about 3 mol% to about 12 mol%; b) SO2 present from about 48 mol%
to about 75 mol%; c) R'20 present from greater than 0 mol% to about 45 mol%;
and wherein R'20 comprises Li2O, Na2O, 1<20, Ag20, Cu20, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase. It is understood that any of the components disclosed herein can comprise any amounts as disclosed in mentioned above compositions.
[139] In still further aspects, the methods disclosed herein provide for the ion-exchanged glass-ceramic composition comprising a compressive stress layer. It is understood that the compressive stress layer formed by the disclosed methods can exhibit any properties described above and have any thickness or depth as described above. In yet further aspects, the properties of the compressive stress layer can be tuned by various ion-exchange treatment steps, such as a single ion-exchange step or multiple ion-exchange procedures, as described above.
[140] It is further understood that in certain aspects, the amount and a type of ions added through the ion-exchange can affect the transparency of the composition.
Yet, in other aspects, the amount and a type of ions added through the ion-exchange can affect the coefficient of thermal expansion (CTE) of the composition. VVithout being bound by theory, the addition of alkali oxide, for example, can increase the coefficient of thermal expansion (CTE) and/or lower the chemical durability of the glasses and/or glass-ceramics.
[141] In still further aspects, the glass-ceramic compositions and the ion-exchanged glass-ceramic compositions can exhibit any of the disclosed above characteristics and properties. In such exemplary aspects, these compositions can be transparent, translucent, or opaque and have any of the disclosed above medium grain sizes.
[142] In still further aspects, the methods disclosed herein comprise a step of forming a glass-ceramic article. Any known in the art methods of forming or shaping an article can be utilized. For example, and without limitation, the methods of forming a glass-ceramic article can comprise down drawing (by either a slot draw or fusion draw process), float processing, or thin rolling the glass. In yet other aspects, the methods can comprise shaping the glass or glass-ceramic to any desired shape.
Various shaping methods can also be used, such as casting, molding, pressing, rolling, floating, and the like. In yet further aspects, the articles disclosed herein can be formed by a float/flat glass press process, a press-and-blow process, a blow-and-blow process, or any combination thereof [143] In still further aspects, the articles formed by the disclosed herein methods can comprise a hollowware, tableware, container, plate, sheet, float/flat sheet, cookware, powder, fiber, cones, spheres, blades, or any combination thereof.
EXAMPLES
[144] The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the compounds, compositions, articles, devices, and/or methods claimed herein are made and evaluated and are intended to be purely exemplary and are not intended to limit the disclosure. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.), but some errors and deviations should be accounted for.
1:14.5] The LAS glass-ceramics samples were prepared using the powder of Li2CO3 (Alfa Aesar, USA, 99%), SiO2 (Alfa Aesar, USA, 99.5%), Al2O3 (Alfa Aesar, USA, 99.5%), H3B03(Acros Organics, USA, 99+%), Na2CO3(J.T.Baker, USA), Al(P03)3 (Alfa Aesar, USA), ZrO2 (Fisher Chemical, USA). The compositions of Li2CO3, SiO2, and Al2O3 are mainly based on the phase diagram of Si02-A1203-Li20 (as shown in FIG. 1, M. Krishna Murthy et al., Phase equilibria in the system lithium metasilicate¨
f3-eucryptite, J. Am. Ceram, Soc. 37 (1) (1954) 14-17). As the compositions of the residue glass are different from those of crystals, the gradient of Li2O and Al2O3 was investigated to maximize the percent of petalite and fi-spodumene crystals in final glass-ceramics. P205 was used as a nucleation agent to introduce bulk nucleation and accelerate the nucleation rate of crystal phases, and ZrO2 was used to limit the crystal size to obtain transparency. Different amounts of P203 and ZrO2 were investigated to change numbers and sizes of crystals in order to optimize transparency and increase mechanical strength. B203 and N820 were used to promote glass-forming abilities. The compositions of the various glass-ceramic samples as prepared herein are shown in Table 1.
11461 In this example, mixtures of 200 g powders were double melted in a platinum crucible at 1,550 '-=C and kept for 3 and 5 h for homogenization and fining.
Molten glasses were poured on a stainless-steel plate, annealed at 520 C for more than 8 h, and slowly cooled to room temperature in the furnace to release thermal stress. The homogeneity was verified using Polariscope to avoid unwanted nucleation and crystal growth in glass-ceramics.
[147] Glass samples were cut into small pieces and prepared for ceramming.
Different temperatures were selected for nucleation temperature, in a small range above the glass transition temperature (Tg) measured by Differential Scanning Calorimetry (DSC). Different were selected for crystal growth, according to the crystallization temperature measured by DSC. Small glass pieces were kept at nucleation temperature for 4 h, increased to crystal growth temperature at 10 C/min, held for 4 h for crystal growth, and slowly cooled down to room temperature in the furnace.
[148] Glass samples were ground into a powder and measured by Inductively Coupled Plasma Atomic Emission Spectroscopy (ICP-AES) to investigate the compositional differences between glass samples and batch materials. DSC
measurement performed heat-cool-heat experiments at 10 C/min using SDT 600 from TA company to learn glass transition temperature and crystallization temperature. The cooling process provides a known thermal history, and Tg was recorded as the onset temperature in the glass transition area. Viscosity-temperature parameters were measured using a rotational viscometer (VIS 403, TA
Instruments) at a 20 K/min cooling rate in the range of 10 3-10" Pa-s. The observed high cooling rate was assumed to be due to the crystallization of the supercooled liquid of lithium aluminosilicate glass.
[149] Densities of both glass and glass-ceramics were measured using the Archimedes method with distilled water as a liquid medium at room temperature.
X-ray diffraction (XRD) patterns (20 from 10 to 70 ) were obtained to identify crystal phases and calculate the percent of different crystals using PANalytical Empryean X-ray Diffractometer with Cu Ka radiation (40 kV& 40 rnA) source.
[150] Ultraviolet-visible (UV-VIS) transmittance spectra in a range from 250 to 800 nm were obtained using Perkin-Elmer Lambda 950 UV-VIS-NIR Spectrophotometer.
The glass-ceramics samples for UV-VIS spectra were optically polished to equal thickness (2.0 0.1 mm).
Table 1. The composition of LAS glass-ceramics batch materials.
LAS.11-6 LAS7 LASS LAS9 LAS10 LAS11 LAS12 mol% mol% mol% mol% mol% mol% mol%
S102 68.3 69.5 67.1 65.9 68.3 68.3 68.3 A1203 9.4 9.4 9.4 9.4 5.4 7.4 3.4 B203 0.6 0.6 0.6 0.6 0.6 0.6 0.6 L120 18.5 18.5 18.5 18.5 22.5 20.5 24.5 Na2O 1.6 1.6 1.6 1.6 1.6 1.6 1.6 K20 0.0 0.0 0.0 0.0 0.0 0.0 0.0 Zr02 1.2 0.0 2.4 3.6 1.2 1.2 1.2 P205 0.6 0.6 0.6 0.6 0.6 0.6 0.6 Total 100 100 100 100 100 100 100 mol% mol% mol% mol% mol% mol% mol%
SiO2 68.3 67.1 67.1 67.1 68.9 66.9 64.9 A1203 11.4 7.4 5.4 3.4 5.4 5.4 5.4 8203 0.6 0.6 0.6 0.6 0.0 2.0 4.0 Li2O 16.5 20.5 22.5 24.5 22.5 22.5 22.5 N a20 1.6 1.6 1.6 1.6 1.6 1.6 1.6 K20 0.0 0.0 0.0 0.0 0.0 0.0 0.0 Zr02 1.2 2.4 2.4 2.4 1.2 1.2 1.2 P20s 0.6 0.6 0.6 0.6 0.6 0.6 0.6 Total 100 100 100 100 100 100 100 mol% mol% mol% mol% mol% mol% mol%
Si02 68.9 67.7 67.1 67.7 68.3 68.3 69.1 A1203 5.4 9.4 5.4 5.4 6.4 4.4 7.4 B203 0.6 0.6 0.6 0.6 0.6 0.6 0.6 Li20 22.5 18.5 22.5 22.5 21.5 23.5 18.5 N a20 1.6 1.6 1.6 1.6 1.6 1.6 1.6 K20 0.0 0.0 0.0 0.0 0.0 0.0 0.0 ZrO2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 P205 0.0 1.2 1.8 1.2 0.6 0.6 1.8 Total 100 100 100 100 100 100 100 [151] Vickers hardness and toughness were determined by using a Mitutoyo HM-200 microhardness tester. At least 10 indents were measured on the polished surface of each sample under a 136 diamond indenter. The hardness was measured under 0.1 kgf (1 kgf=9.8 N) and calculated following Equation (1):
1-117 = 0.0182-1Laz (1);
d t where HV is the Vickers hardness in GPa, F is the load in kgf, and dr and d2 are the lengths of two diagonals left by indenter in mm. Vickers toughness was measured under 0.8 kgf and calculated using Equation (2):
_6 (E)" P
= 0.016 x 10 ¨FT (-)1. (2);
co 5 where Kic is the indentation fracture toughness in MPa=m", E is the elastic Young's modulus in GPa, H is the hardness in GPa, P is the load in N, Co is half of the diagonal crack length in m. Elastic modulus is measured using nanoindentation.
Indentation test is used for fracture toughness, instead of three-point bending test in current research, for the reason of low dimensional requests and fewer sample numbers.
[152] It was found that the number of cracks in the indentation test increases with increasing load following the sigmodal-like shape. Weibull's equation was used to fit the curve of sodium aluminosilicate glasses by Yoshida et al. and calcium aluminosilicate glasses by POnitzsch at al. (Yoshida. A. at al., Crack initiation behavior of sodium aluminosilicate glasses. J. of Non-Cryst. Solids 344 (1-2) (2004) 37-43; A. POnitzsch et al., Bulk elastic properties, hardness, and fatigue of calcium aluminosilicate glasses in the intermediate-silica range. J. of Non-Cryst.
Solids 434 (2016) 1-12).
[153] Weibull's equation is shown in Equation (3):
F(P) = I ¨ exp [¨ (Er (3) where F(P) is the probability of cracks (the number of ideal cracks divided by four), P
is the load, p is the scale parameter, and m is the Weibull modulus. The crack resistance is defined as F(P)=0.5, meaning the load required to generate two out of four cracks.
[154] Linear thermal expansion coefficient (CTE) of glass-ceramics samples were obtained under 0.0500 N force using a Thermomechanical Analyzer (TMA) Q400 from the TA company. The samples were ground to 6x6x20 mm, and heated from room temperature to 300 C at a 5 C /min heating rate.
Glass composition [155] It was found that the composition from 1CP data is very close to that of batch materials, with an error of less than 0.5 mol% for major oxides and 0.2 mol%
for minor oxides. Due to the evaporation loss, the amounts of P205, 1.120, B203 were found to be less than that of the batch materials, causing the increasing percent of 6102 and A1203 in glass compositions. Due to the large atomic mass and high melting point, the amount of Zr02 in the glass was found to be slightly less than that in the batch materials.
Crystal phases [156] It was further found that the types of the crystal phases from the XRD
pattern mainly change with the amount of A1203 and Si02 when Li20 is kept in excess amount. When the molar percent of A1203: 1.120: S102 is from 5.4:22.5:68.3 to 7.4:20.5:68.3, the main crystal phases are petalite and LiAlSi308, with Li2SiO3 as a minor phase (FIG. 2A).
[157] Without wishing to be bound by any theory, based on the XRD pattern, LiAlSi308 is believed to be the solid solution of 8-spodumene due to similar peak positions. When the amount of A1203 is more than 7.4 mol%, the XRD shows the only presence of the 6-spodumene solid solution, as the petalite phase does not appear in the XRD pattern (FIG. 2B). Again, without wishing to be bound by any theory, it was hypothesized that L1A1S1308 is more preferable to crystalize than petalite (LiAlSiaOio), as the ratio of LiA102:Si02 is higher in LiAlSi308.
[158] It was also found that when A1203 is lower than 5.4 mol%, the crystal peak at 281,-38.4 becomes intensive (FIG. 2B). This peak is several times higher than others when the amount of A1203 is decreases to 3.4 mol%. Again, without wishing to be bound by any theory, this intensive peak (the plane (002) of Li2SiO3) is believed to be due to the anisotropic growth of lithium metasilicate crystals in glass-ceramics. When the amount of 6102 is too high compared with A1203, the crystal of 6102 can be present in the XRD pattern (FIG. 2B). Further, without wishing to be bound by any theory, it was found that the nucleation and crystal growth temperatures do not influence the types of crystal phases but influence the ratios of different crystals. The peak of the 13-spodumene solid solution was found to be more intensive, while the lithium metasilicate peak has disappeared at high temperatures.
059] As the crystal growth rate of transparent glass-ceramics is far less than the maximum growth rate, the crystalline to amorphous ratio continuously increases with increasing crystal growth temperature. This ratio can also be influenced by the amount of P205, B203, and Zr02. Again, without wishing to be bound by any theory, it is assumed that large Zr atoms increase the activation barrier, and thus, leading to the decrease of the frequency of successful jumps of atoms from liquid to crystals.
As a result, the crystalline to amorphous ratio largely decreases with more amount of Zr02. P205, as the nucleation agent, can decrease the nucleation temperature and increase the nucleation rate, and thus, resulting in an increase of crystalline to amorphous ratio. B203 has less influence on the ratio than Zr02 and P205. But high amount of B203 can lead to a decrease in the viscosity at crystal growth temperature, which slightly decreasing the activation barrier for the movement of atoms from liquid to crystals, and thus, causing the increase of crystalline to amorphous ratio.
DSC pattern and viscosity [160] Variations in glass transition temperature, melting point (TO, and crystallization temperature were investigated as a function of Li20 and A1203 amounts (FIG.3A-B). It was found that Tg linearly increases with an increasing amount of A1203 and a decreasing amount of Li20 (F1G.3B). It was found that Tg is 484 C for sample 12 with 3.4 mol% A1203 and 24.5 mol% Li20, increasing around 60 C for sample 13 with 11.4 mol% A1203 and 16.5 mol% Li20. It was further found that Tm decreases with an increasing amount of A1203 and a decreasing amount of Li20.
[161] Without wishing to be bound by any theory, the crystallization peak around 750 C is believed to be the peak of f3-spodumene solid solution, according to the phase diagram of LiA102-Si02 (FIG.4). The depth of this peak decreases with a decreasing amount of A1203, indicating that the 13-spodumene solid solution is less preferable in the low concentration of A1203. It was further found that in sample LAS12 with 3.4 mol% A1203, the negative peak at 723 C appears, which can possibly correspond to the melting point of Li2SiO3. Analysis of this sample also has shown the appearance of another crystallization peak around 860 C. Which wishing to be bound by any theory, this peak was attributed to 8-spodumene based on the phase diagram. No peaks of petalite were observed in the DSC pattern. Again, without wishing to be bound by any theory, it was hypothesized that such phenomena are due to the possible slow growth of petalite, compared with the Cimin heating rate in DSC. Again, without wishing to be bound by any theory, it was further hypothesized that this slow growth is responsible for the glass-ceramics samples staying transparent while being in the furnace for hours.
(1621 The viscosity-temperature curves of LAS10 and LAS11, as shown in FIGS.
5A-B were also compared with standard soda lime silicate glass (SG 80(a)). It was found that both LAS10 and LAS11 crystallize around 950 C at a 20 K/min cooling rate. The viscosity of lithium aluminosilicate glass was found to be less than SG80 at high temperatures. The data of LAS11 was then fitted with the Mauro-Yue-Ellison-Gupta-Allan (MYEGA) equation, using -2.93 for logical.. 7.9 fitted in the MYEGA
equation is 451 C, which is 61 C lower than Tg from DSC. Without wishing to be bound by any theory, it was assumed that this error can be due to the limited range of viscosity data at high temperatures. Fragility (m), the parameter useful in understanding liquid dynamics and glass transition behavior, can also be predicted from the MYEGA equation. It was found that the fragility of LAS11 is 27.
Density of glass samples and glass-ceramics samples (163] The densities of the glass samples were measured and were found to be in the range from 2.38 to 2.47 g/cm3, mainly influenced by the amount of ZrO2.
FIG. 6 shows that the densities of glass increase with the amount of ZrO2, Multiple linear regression equation was used to predict the influence of different oxides to the densities of glass (Equation 4):
p(g/cm3)=2.37745+0.00027[A1203]+0.00003[1_120]+0.00078[13203]+0.00000[Na2 0]+0.02481[Zr02]+0.00000(P205) (4) where p is the density, 2.37745 g/cm3 is the predicted density of pure silicate glass from a multiple linear regression equation with a percent error of 8.1%
compared with experimental data (2.20 g/cm3). Again, without wishing to be bound by any theory, this percent error was assumed to be mainly due to the simplified linear model. R2of the fitting model was found to be 0.92, indicating that 92 percent of the variabilities can be explained by the linear regression of different oxides.
From the fitted data, the density of the glass samples is mainly increased with the amount of ZrO2.
[164] It was shown that the densities of the glass-ceramics sample are slightly higher than their mother glass. Without wishing to be bound by any theory, it was assumed that this is due to the crystals in glass-ceramics having ordered structure and less open space. However, it was also found that the densities of glass-ceramics are less than about 2% higher than the density of their mother glass.
Transmittances [165] FIG. 7 shows the transmittance of different glass-ceramics samples prepared herein. The first number in the glass-ceramics, as shown in FIG. 7, refers to the nucleation temperature and nucleation time, and the second one refers to the crystal growth temperature and crystal growth time. It was found that most of the samples, except for sample LAS 26, exhibited the average transmittances in the visible light region (390-700 nm) higher than about 80% (Table 2).
Table 2. The transmittance of exemplary glass-ceramics samples.
T,% LAS10 LAS11 LAS24 LAS26 Ave. Trans. at 390 81.3 83.0 87.7 38.4 nm-700nm Trans. at 550 nm 82.6 84.5 88.2 40.9 Trans. at 400 nm 72.1 72.3 86.3 72.5 [166] It was further found that most of the investigated samples were transparent at low crystal growth temperature and tended to become translucent and opaque at a higher crystal growth temperature. Further, it was found that the samples containing a high amount of lithium metasilicate tended to be translucent or opaque at the low crystal growth temperature. Without wishing to be bound by any theory, it was assumed that transparency of the glass-ceramic compositions correlates with the anisotropic growth of lithium metasilicate, corresponding to the intensive peak in the XRD pattern.
[167] Further, samples containing a high amount of 8-spodumene solid solution were found to be transparent at the high crystal growth temperature. It was found, as shown in the DSC pattern, while 8-spodumene crystallizes at a higher temperature, compared to petalite and lithium metasilicate crystallization, the 8-spodumene crystals are smaller than petalite and lithium metasilicate crystals at the same crystal growth temperature.
Microstructure [168] FIGS. 8A-8C show the secondary electron images of the microstructure of opaque, translucent, and transparent LAS glass-ceramics from SEM. Due to the different chemical durability of crystals and glass to hydrofluoric acid, crystals are observed under the electron microscope. It shows that the crystal sizes increase with crystal growth temperature and exposure time. The crystal sizes of transparent glass ceramics are between 20 and 40 nm, which were measured directly under SEM.
Some small pits were observed on the surface of crystals due to the etching of hydrofluoric acid through the dislocations of crystals.
Vickers hardness and crack resistance [169] Indentation hardness and toughness of the exemplary samples disclosed herein are shown in Table 3. PPG, a standard soda lime silicate glass with 74 mol%
SiO2, 13.3 mol% Na2O, 8.3 mol% CaO, 0.06 mol% A1203 and 3.7 mol% MgO [43], were measured under the same condition. Indentation hardness of glass-ceramics samples, increasing with higher crystal growth temperature, was far higher than that of PPG. The indentation toughness of glass-ceramics samples was higher than that of soda-lime silicate glass (0.75 MPa-m12) and Pyrex (0.70 MPa=m1/2). Samples with a higher amount of Al2O3 were found to have higher indentation hardness and toughness.
[170] FIGS. 9A-B show the crack probabilities of glass-ceramics samples with different loads of indenters, compared with that of PPG. R2 of the Weibull distribution on different samples was greater than 0.87. The average crack resistance of the samples was found to be 0.56 kgf, or four times higher than that of PPG.
Without wishing to be bound by any theory, it was assumed that this high crack resistance is the result of the ceramming process. The interlocking microstructure created from crystal grains in glass-ceramics can promote crack bridging and deflection and thus, lead to an increase in crack resistance.
Thermal expansion coefficients [171] FIG. 10 shows the linear thermal expansion coefficients (GTE) obtained from TMA in the range from 25 C to 300 C for both IASI 0 and LAS11 glass and glass-ceramics The thermal expansion coefficients of glass-ceramics were found to be in the range of 40-90x10-7/ C, significantly higher than that of SiO2 glass (5.5x 1 0.7 / C). GTE of glass-ceramics was found to be lower than the corresponding glass, indicating that GTE of petalite and 8-spodumene crystals are lower than the glass matrix. GTE was higher in samples with a higher amount of Li2O.
[172] The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) "means for or "step for, respectively.
[173] In view of the described processes and compositions, hereinbelow are described certain more particularly described aspects of the inventions. These particularly recited aspects should not, however, be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the "particular" aspects are somehow limited in some way other than the inherent meanings of the language and formulas literally used therein.
Table 3. Indentation hardness and toughness of LAS glass-ceramics Sample Glass 58045904 58046104 58046304 Indentation 5.92 0.34 GPa 7.20 0.15 GPa 7.19 0.16 GPa 7.64 0.34 GPa Hardness Indentation 0.9510.02 0.9710.04 0.91-10.04 0.8910.05 Toughness MPa=M1/2 MPa= M1/2 MPa=m1/2 mpa.m1/2 Sample IASI LAS10 LAS10 LAS10 580.4 730 4 580 4 750 4 580 4 770_4 5804 790_4 Indentation 7.7710.26 GPa 7.7210.20 GPa 7.7010.18 GPa 7.9010.25 GPa Hardness Indentation 1.05 0.04 1.19 0.09 1.20 -0.03 1.28 0.07 Toughness MPa=M1/2 MPa=m1/2 MPa=M1/2 MPa=m1/2 Sample LAS11 LAS11 LAS11 LAS11 Glass 580_4 590_4 580_4 610_4 580_4 6304 Indentation 6.03 0.17 GPa 6.30 0.08 GPa 7.96 0.13 GPa 7.80 0.50 GPa Hardness Indentation 0.98-10.02 1.13-10.05 0.88-10.02 0.9110.13 Toughness MPa.m1/2 MPa.m112 NAPa=m1/2 MPa=m112 Sample LAS11 LAS11 LAS11 Soda-lime 5804 730_4 580_4 750_4 580_4 770_4 silicate glass(PPG) Indentation 7.81-10.28 GPa 7.7910.19 GPa 7.81-10.28 GPa 5.35-10.07 GPa Hardness Indentation 1.08 0.02 1.36-10.06 1.23-10.04 0.75-10.01 Toughness MPa-M/12 MPa-li1/12 mpa.m1/2 mpa.m1/2 ASPECTS:
[174] Aspect 1: A glass-ceramic composition comprising: from about 2 mol% to about 20 mol% of A1203. from about 2 mol% to about 45 mol% of Li20; and from about 48 mol% to about 80 mol% of Si02: having a p-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase.
[175] Aspect 2: The glass-ceramic composition of Aspect 1, wherein A1203 is present from about 5 mol% to about 7.5 mol %, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase and from about 20 to about 80% of the petalite phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
[176] Aspect 3: The glass-ceramic composition of Aspect 2, wherein Li20 is present from about 20 mo10/0 to about 25 mol%.
[177] Aspect 4: The glass-ceramic composition of Aspect 1, wherein A1203 is present from about 7 mol% to about 12 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the p-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
[178] Aspect 5: The glass-ceramic composition of any one of Aspects of 1-4, wherein the lithium silicate crystalline phase comprises a lithium metasilicate crystalline phase.
[179] Aspect 6: The glass-ceramic composition of any one of Aspects 1-5, further comprising from 0 mol% to about 8 mol% of B203, from 0 mol% to about 8 mol% of Zr02, from 0 mol% to about 5 mol% of P205, and from 0 mol% to about 5 mo10/0 of Na20.
[180] Aspect 7: The glass-ceramic composition of any one of Aspects 1-6, wherein the composition exhibits density from about 2.00 g/cm3 to about 2.6 g/cm3.
[181] Aspect 8: The glass-ceramic composition of any one of Aspects 1-7, exhibiting an average transmittance greater than about 80% over a wavelength range from about 390 nm to about 700 nm as measured for a sample prepared from the composition and having a thickness of about 2.00 mm.
[182] Aspect 9: The glass-ceramic composition of any one of Aspects 1-7, exhibiting an average transmittance between 20% and 80% over a wavelength range from about 390 nm to about 700 nm as measured for a sample prepared from the composition and having a thickness of about 2.00 mm.
[183] Aspect 10: The glass-ceramic composition of any one of Aspects 1-7, exhibiting an average transmittance lower than 20% over a wavelength range from about 390 nm to about 700 nm as measured for a sample prepared from the composition and having a thickness of about 2.00 mm.
[184] Aspect 11: The glass-ceramic composition of Aspect 8, comprising a plurality of crystal grains, wherein the median size of a crystal grain is from about 20 to about 80 nm.
[185] Aspect 12: The glass-ceramic composition of Aspect 9, comprising a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 80 nm to about 500 nm.
[186] Aspect 13: The glass-ceramic composition of Aspect 10, comprising a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 500 nm.
[187] Aspect 14: The glass-ceramic composition of any one of Aspects 1-13, exhibiting Vickers hardness equal to or greater than about 6.0 GPa.
[188] Aspect 15:The glass-ceramic composition of any one of Aspects 1-14, exhibiting Vickers hardness of at least about 5% greater than Vickers hardness of a standard soda lime silicate glass.
[189] Aspect 16: The glass-ceramic composition of any one of Aspects 1-15, exhibiting a crack-resistance greater than about 0.2 kgf.
[190] Aspect 17: The glass-ceramic composition of any one of Aspects 1-16, exhibiting a crack-resistance greater than about 0.4 kgf.
[191] Aspect 18: The glass-ceramic composition of any one of Aspects 1-17, exhibiting a crack-resistance that at least 4 times higher than a crack-resistance of a standard soda lime silicate glass.
[192] Aspect 19: The glass-ceramic composition of any one of Aspects 1-18 exhibiting a thermal expansion coefficient from about 40x107 to about 90x107 /
C.
[193] Aspect 20: The glass-ceramic composition of any one of Aspects 1-19, wherein the composition exhibits a glass transition temperature (Tg) from about 450 C to about 600 C.
[194] Aspect 21: The glass-ceramic composition of any one of Aspects 1-20, wherein the composition further comprises one or more of fining agents selected from Ce02, Sn02, Fe2O3. As203, Sb203, Mn02, or a combination thereof, and wherein the one or more fining agents are present in a total amount equal to or less than about 1 mol [195] Aspect 22: The glass-ceramic composition of any one of Aspects 1-21, further comprising one or more of coloring components selected from transition metal oxides and/or rare earth metal oxide, and wherein the one or more coloring components are present in a total amount equal to or less than about 1 mol%.
[196] Aspect 23: The glass-ceramic composition of any one of Aspects 1-22, further comprising a decolorizing agent comprising sodium sulphate, selenium compounds, erbium oxide, cerium oxide, cobalt oxide, manganese oxide, or any combination thereof.
[197] Aspect 24: The glass-ceramic composition of any one of Aspects 1-23, wherein the composition is ion-exchangeable.
[198] Aspect 25: A glass-ceramic composition comprising: Al2O3 present from about 2 mol% to about 20 mol%, SiO2 present from about 48 mol% to about 80 mol%; R'20 present from greater than 0 mol% to about 45 mol%, and wherein R'20 comprises Li2O. Na2O, K20, Ag2O, Cu2O, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase.
[199] Aspect 26: The glass-ceramic composition of Aspect 25, wherein when R'20 comprises 1..i20, the composition comprises a minor crystalline phase comprising a lithium silicate phase.
[200] Aspect 27: The glass-ceramic composition of Aspect 25 or 26, wherein Al2O3 is present from about 5 mol% to about 7.5 mol %, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of thef3-spodumene phase and from about 20 to about 80% of the petalite phase.
[201] Aspect 28: The glass-ceramic composition of Aspect 26, wherein A1203 is present from about 5 mol% to about 7.5 mol A) and Li2O is present from 20 mol% to about 25 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase and from about 20 to about 80% of the petalite phase, and a minor phase comprises up to 10 mol%
of the lithium silicate phase.
[202] Aspect 29: The glass-ceramic composition of Aspect 25 or 26, wherein A1203 is present from about 7 mol% to about 12 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the p-spodumene phase.
[203] Aspect 30: The glass-ceramic composition of Aspect 26, wherein A1203 is present from about 7 mol% to about 12 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the p-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
[204] Aspect 31: The glass-ceramic composition of any one of Aspects 25-30, wherein the composition further comprises: B203 present from 0 mol% to about 8 mol%, ZrO2 from 0 mol% to about 8 mol%, and P205 from 0 mol% to about 5 mol%.
(2051 Aspect 32: The glass-ceramic composition of any one of Aspects 25-31, wherein the composition is transparent, translucent, or opaque.
[206] Aspect 33: The glass-ceramic composition of any one of Aspects 25-32, comprising a compressive stress layer.
[207] Aspect 34: The glass-ceramic composition of any one of Aspects 25-33, wherein the composition exhibits density from about 2.00 g/cm3 to about 2.6 g/cm3.
[208] Aspect 35: The glass-ceramic composition of any one of Aspects 32-34, wherein the composition is transparent and comprises a plurality of crystal grains, wherein the median size of a crystal grain is from about 20 to about 80 nm.
[209] Aspect 36: The glass-ceramic composition of any one of Aspects 32-34, wherein the composition is translucent and comprises a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 80 nm to about 500 nm.
[210] Aspect 37: The glass-ceramic composition of any one of Aspects 32-34, wherein the composition is opaque and comprises a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 500 nm.
[211] Aspect 38: The glass-ceramic composition of any one of Aspects 25-37.
exhibiting Vickers hardness equal to or greater than about 6.0 GPa.
[212] Aspect 39: The glass-ceramic composition of any one of Aspects 25-38, exhibiting Vickers hardness of at least about 5% greater than Vickers hardness of a standard soda lime silicate glass.
[213] Aspect 40: The glass-ceramic composition of any one of Aspects 25-39, exhibiting a crack-resistance greater than about 0.2 kgf.
[214] Aspect 41: The glass-ceramic composition of any one of Aspects 25-40, exhibiting a crack-resistance greater than about 0.4 kgf.
[215] Aspect 42: The glass-ceramic composition of any one of Aspects 25-41, exhibiting a crack-resistance that at least 4 times higher than a crack-resistance of a standard soda lime silicate glass.
[216] Aspect 43: The glass-ceramic composition of any one of Aspects 25-42, exhibiting a thermal expansion coefficient from about 40x107 to about 90x10-71 C.
[217] Aspect 44: The glass-ceramic composition of any one of Aspects 25-43, wherein the composition exhibits a glass transition temperature (Tg) from about 450 C to about 600 (C.
[218] Aspect 45: The glass-ceramic composition of any one of Aspects 25-44, wherein the composition further comprises one or more fining agents selected from Ce02, Sn02, Fe2O3, A5203, Sb203, Mn02, or a combination thereof, and wherein the one or more fining agents are present in a total amount equal to or less than about 1 mol %.
[219] Aspect 46: The glass-ceramic composition of any one of Aspects 25-45, wherein the composition further comprises a decolorizing agent comprising sodium sulphate, selenium compounds, erbium oxide, cerium oxide, cobalt oxide, manganese oxide, or any combination thereof.
[220] Aspect 47: The glass-ceramic composition of any one of Aspects 25-46, further comprising one or more coloring components selected from transition metal oxides and/or rare earth metal oxide, and wherein the one or more coloring components are present in a total amount equal to or less than about 1 mol0/0.
[221] Aspect 48: The glass-ceramic composition of any one of Aspects 25-47, wherein Ag2O, and/or Cu2O, and/or CuO is present and wherein the glass-ceramic composition exhibits antimicrobial, antiviral, antibacterial, and/or antifungal properties.
[222] Aspect 49: A glass-ceramic article comprising the composition of any one of Aspects 1-48.
[223] Aspect 50: A glass-ceramic article comprising the composition of any one of Aspects 33-48, wherein the compressive stress layer extends from a surface of the article to a depth of the compressive stress layer, and wherein the depth is from about 1 pm to about 100 pm.
[224] Aspect 51: A glass-ceramic article comprising the composition of any one of Aspects 33-48, wherein the compressive stress layer extends from a surface of the article to a depth of the compressive stress layer, and wherein the depth is up to about 25 % of a thickness of the glass-ceramic article.
[225] Aspect 52: A glass-ceramic article comprising: from about 2 mol% to about 20 mol% of A1203; from about 2 mol% to about 45 mol% of Li20, and from about mol% to about 80 mol% of SiO2; having a 13-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase.
[226] Aspect 53: A glass-ceramic article comprising: A1203 present from about mol% to about 20 mol%; SiO2 present from about 48 mol% to about 80 mol%; and R'20 present from greater than 0 mol% to about 45 mol%, wherein R'20 comprises Li20, Na20, 1(20, Ag20, Cu20, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising al3-spodumene phase, and optionally, a petalite phase.
[227] Aspect 54: The article of any one of Aspects 49-53, wherein the article comprises a hollowware, tableware, container, plate, sheet, float/flat sheet, cookware, powder, fiber, cones, spheres, blades, or any combination thereof.
[228] Aspect 55: The article of any one of Aspects 49-54, wherein the article is formed by a float/flat glass press process, a press-and-blow process, a blow-and-blow process, or any combination thereof.
[229] Aspect 56: A tableware comprising the composition of any one of Aspects 48.
[230] Aspect 57: The tableware of Aspect 56. wherein the tableware is formed by a glass press process, a press-and-blow process, and/or a blow-and-blow process.
[231] Aspect 58: A hollowware comprising the composition of any one of Aspects 1-48.
(.232] Aspect 59: The hollowware of Aspect 57, wherein the hollowware is formed by a glass press process, a press-and-blow process, and/or a blow-and-blow process.
[233] Aspect 60: A powder comprising the composition of any one of Aspects 1-48.
[234] Aspect 61: A cookware comprising the composition of any one of Aspects 1-48.
(.235] Aspect 62: The cookware of Aspect 61, wherein the cookware is formed by a glass press process, a press-and-blow process, and/or a blow-and-blow process.
[236] Aspect 63: A fiber comprising the composition of any one of Aspects 1-48.
(.237] Aspect 64: The fiber of Aspect 63, wherein the fiber is formed by a continuous or discontinuous fiber drawing or spinning process.
[238] Aspect 65: A float or flat glass press product comprising the composition of any one of Aspects 1-48.
[239] Aspect 66: A press-and-blow process product comprising the composition of any one of Aspects 1-48.
[240] Aspect 67: A blow-and-blow process product comprising the composition of any one of Aspects 1-48.
[241] Aspect 68: A method comprising: forming a mixture comprising: a) from about 2 mol% to about 20 mol% of A1203. from about 2 mol% to about 45 mol% of Li2O; and from about 48 mol% to about 80 mol% of SiO2; b) forming a homogeneous composition; and c) ceramming the homogeneous composition to form a glass-ceramic composition.
(242] Aspect 69: The method of Aspect 68, wherein the mixture further comprises from 0 mol% to about 8 mol% of Zr02, or from 0 mol% to about 5 mol% of P205, or a combination thereof.
[243] Aspect 70: The method of Aspect 68 or 69, wherein the step of forming the homogenous composition comprises melting the mixture in a furnace at a temperature from about 1,300 C to about 1,700 C for a first predetermined time.
[244] Aspect 71: The method of Aspect 70, further comprising a step of annealing at a temperature from about 450 C to about 700"C.
[245] Aspect 72: The method of any one of Aspects 68-71, wherein the step of ceramming comprises heating the homogenous composition at a nucleation temperature for a second predetermined time.
[246] Aspect 73: The method of Aspect 72, wherein the nucleation temperature is from about 450 C to about 650 "C.
[247] Aspect 74: The method of Aspect 71 or 72, wherein the step of ceramming further comprises a step of heating the composition to a crystallization temperature at a rate from about 5 C/min to about 15 C/min and keeping the composition at the crystallization temperature for a third predetermined time.
[248] Aspect 75: The method of Aspect 74, wherein the crystallization temperature is from about 580 C to about 800 C.
[249] Aspect 76: The method of any one of Aspects 74-75, wherein the first, the second, and/or the third predetermined times are from about 3 to 5 hours.
[250] Aspect 77: The method of any one of Aspects 72-76, wherein P205 is a nucleation agent.
[251] Aspect 78: The method of any one of Aspects 74-77, wherein Zr02 is a crystal size growth-limiting agent.
[252] Aspect 79: The method of any one of Aspects 68-78, wherein the glass-ceramic composition comprises a 13-spodumene phase, optionally petalite phase, and a lithium silicate crystalline phase.
[253] Aspect 80: The method of Aspect 79, wherein Al2O3 is present from about mol% to about 7.5 mol %, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase and from about 20 to about 80% of the petalite phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
[254] Aspect 81: The method of Aspect 80, wherein Li2O is present in the composition from about 20 mol% to about 25 mol%.
[255] Aspect 82: The method of Aspect 81, wherein Al2O3 is present from about mol% to about 12 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of theii-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
[256] Aspect 83: The method of any one of Aspects 80-82, wherein the lithium silicate crystalline phase comprises a lithium metasilicate crystalline phase.
[257] Aspect 84: The method of any one of claims 68-83, wherein the mixture further comprises from 0 mol% to about 8 mol% of B203, and from 0 mol% to about 8 mol% of Na2O.
[258] Aspect 85: The method of any one of Aspects 68-84, further comprising a step of ion exchange treatment comprising exposure to a salt bath, spray, paste, a vapor-assisted ion exchange, a plasma-assisted ion exchange, or any combination thereof.
[259] Aspect 86: The method of Aspect 85, wherein the ion exchange treatment is electrically accelerated.
[260] Aspect 87: The method of Aspect 85 or 86, wherein the step of ion-exchange treatment comprises placing the glass-ceramic composition into a molten salt bath comprising sodium, potassium, silver, or copper (1) ions, or a combination thereof at conditions effective to provide an ion-exchanged glass-ceramic composition.
[261] Aspect 88: The method of Aspect 87, wherein the ion-exchanged glass-ceramic composition comprises: Al2O3 present from about 2 mol% to about 20 mol%;
SiO2 present from about 48 mol% to about 80 mol%; R'20 present from greater than 0 mol% to about 45 mol%; and wherein R'20 comprises L120, Na2O, K20, Ag2O, Cu2O, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase.
[262] Aspect 89: The method of Aspect 87 or 88, wherein the conditions effective to provide the ion-exchanged glass-ceramic composition comprise exposure of the glass-ceramic composition to a molten salt at a temperature from about 380 C
to about 500 C for a time period from about 4 hours to about 20 hours.
[263] Aspect 90: The method of any one of Aspects 87-89, wherein the ion-exchanged glass-ceramic composition comprises a compressive stress layer.
[264] Aspect 91: The method of any one of Aspects 68-90, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit density from about 2.00 g/cm3 to about 2.6 g/cm3.
[265] Aspect 92: The method of any one of Aspects 68-91 wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit an average transmittance greater than about 80% over a wavelength range from about 390 nm to about 700 nm for a sample formed from the glass-ceramic and/or the ion-exchanged glass-ceramic composition and having a thickness of about 2.00 mm.
[266] Aspect 93: The method of any one of Aspects 68-92, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit an average transmittance between 20% and 80% over a wavelength range from about 390 nm to about 700 nm as measured for a sample formed from the glass-ceramic and/or the ion-exchanged glass-ceramic composition and having a thickness of about 2.00 mm.
[267] Aspect 94: The method of any one of Aspects 68-93, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit an average transmittance lower than 20% over a wavelength range from about 390 nm to about 700 nm as measured for a sample formed from the glass-ceramic and/or the ion-exchanged glass-ceramic composition and having a thickness of about 2.00 mm.
[268] Aspect 95: The method of Aspect 94, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition comprise a plurality of crystal grains, wherein a size of a crystal grain is from about 20 to about 80 nm.
[269] Aspect 96: The method of Aspect 95, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition comprises a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 80 nm to about 500 nm.
[270] Aspect 97: The method of Aspect 96, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition comprise a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 500 nm.
(271] Aspect 98: The method of any one of Aspects 68-97, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit Vickers hardness equal to or greater than about 6.0 GPa.
[272] Aspect 99: The method of any one of Aspects 68-98, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit Vickers hardness of at least about 5% greater than Vickers hardness of a composition comprising a standard soda lime silicate glass.
[273] Aspect 100: The method of any one of Aspects 68-99, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit a crack-resistance greater than about 0.2 kgf.
[274] Aspect 101: The method of any one of Aspects 68-100, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit a crack-resistance greater than 0.4 kgf.
[275] Aspect 102: The method of any one of Aspects 68-101, wherein the glass-ceramic composition exhibits a crack-resistance that at least 4 times higher than a crack -resistance of a composition comprising a standard soda lime silicate glass.
[276] Aspect103: The method of any one of Aspects 68-102, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit a thermal expansion coefficient from about 40x107 to about 90x10-7 [277j Aspect 104: The method of any one of Aspects 68-103, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit a glass transition temperature Tg from about 450 C to about 600 C.
[278] Aspect 105: The method of any one of Aspects 68-104 further comprising a step of forming a glass-ceramic article.
(279] Aspect 106: The method of Aspect 105, wherein the step of forming the glass-ceramic articles comprises a float or flat press process, a press-and-blow process, a blow-and-blow process, or any combination thereof.
[280] Aspect 107: The method of Aspect 105 or 106, wherein the glass-ceramic article comprises the ion-exchange composition and wherein the compressive stress layer extends from a surface of the article to a depth of the compressive stress layer, wherein the depth is from about 1 pm to about 100 pm.
[281] Aspect 108: The method of any one of Aspects 105-107, wherein the glass-ceramic article comprises the ion-exchange composition and wherein the compressive stress layer extends from a surface of the article to a depth of the compressive stress layer, and wherein the depth is up to about 25 % of a thickness of the glass-ceramic article.
[282] Aspect 109: The method of any one of Aspects 105-108, wherein the article comprises a hollowware, tableware, container, plate, sheet, float/flat sheet, cookware, powder, fiber, cones, spheres. blades, or any combination thereof.
[283] Aspect 110: A method of forming an article comprising forming a composition of any one of Aspects 1-48; and then forming the article, wherein the article comprises a hollowware, tableware, container, plate, sheet, float/fiat sheet, cookware, powder, fiber, cones, spheres, blades, or any combination thereof.
[284] Aspect 111: The method of Aspect 110, wherein the step of forming comprises a float/flat press process, a press-and-blow process, a blow-and-blow process, or any combination thereof.
[285] Aspect 112: The method of Aspect 110 or 111, wherein the step of forming the composition comprises the method of any one of Aspects 68-104.
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Claims (112)
1. A glass-ceramic composition comprising:
a) from about 2 mol% to about 20 mol% of A1203;
b) from about 2 mol% to about 45 mol% of Li20; and c) from about 48 mol% to about 80 mol% of Si02;
having a p-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase.
a) from about 2 mol% to about 20 mol% of A1203;
b) from about 2 mol% to about 45 mol% of Li20; and c) from about 48 mol% to about 80 mol% of Si02;
having a p-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase.
2. The glass-ceramic composition of claim 1, wherein A1203 is present from about 5 mol% to about 7.5 mol %, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase and from about 20 to about 80% of the petalite phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
3. The glass-ceramic composition of claim 2, wherein Li20 is present from about 20 mol% to about 25 mol%.
4 The glass-ceramic composition of claim 1, wherein A1203 is present from about 7 mol% to about 12 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the p-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
5. The glass-ceramic composition of any one of claims 1-4, wherein the lithium silicate crystalline phase comprises a lithium metasilicate crystalline phase.
6. The glass-ceramic composition of any one of claims 1-5, further comprising a) from 0 mol% to about 8 mol% of B203, b) from 0 mol% to about 8 mol% of Zr02, c) from 0 mol% to about 5 mol% of P205, and d) from 0 mol% to about 5 mol% of Na20.
7. The glass-ceramic cornposition of any one of claims 1-6, wherein the composition exhibits density from about 2 00 g/cm3 to about 2.6 g/cm3
8. The glass-ceramic composition of any one of claims 1-7, exhibiting an average transmittance greater than about 80% over a wavelength range from about 390 nm to about 700 nm as measured for a sample prepared from the composition and having a thickness of about 2.00 mm.
9. The glass-ceramic composition of any one of claims 1-7, exhibiting an average transmittance between 20% and 80% over a wavelength range from about 390 nm to about 700 nm as measured for a sample prepared from the composition and having a thickness of about 2.00 mm.
10. The glass-ceramic composition of any one of claims 1-7, exhibiting an average transmittance lower than 20% over a wavelength range from about 390 nm to about 700 nm as measured for a sample prepared from the composition and having a thickness of about 2.00 mm.
11. The glass-ceramic composition of claim 8, comprising a plurality of crystal grains, wherein the median size of a crystal grain is from about 20 to about 80 nm.
12. The glass-ceramic composition of claim 9, comprising a plurality of crystal grains, wherein the median size of a ci-ystal grain is from greater than about 80 nm to about 500 nm.
13.The glass-ceramic composition of claim 10, comprising a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about nm.
14. The glass-ceramic composition of any one of claims 1-13, exhibiting Vickers hardness equal to or greater than about 6.0 GPa.
15. The glass-ceramic composition of any one of claims 1-14, exhibiting Vickers hardness of at least about 5% greater than Vickers hardness of a standard soda lime silicate glass.
16. The glass-ceramic composition of any one of claims 1-15, exhibiting a crack-resistance greater than about 0.2 kgf.
17. The glass-ceramic cornposition of any one of claims 1-16, exhibiting a crack-resistance greater than about 0.4 kgf.
18. The glass-ceramic composition of any one of claims 1-17, exhibiting a crack-resistance that at least 4 tirnes higher than a crack-resistance of a standard soda lime silicate glass.
19. The glass-ceramic composition of any one of claims 1-18 exhibiting a thermal expansion coefficient from about 40x10-7 to about 90x1 0-7 PC.
20. The glass-ceramic composition of any one of claims 1-19, wherein the composition exhibits a glass transition temperature (Tg) from about 450 C to about 600 C.
21.The glass-ceramic composition of any one of claims 1-20, wherein the composition further comprises one or more of fining agents selected from CeO2, Sn02, Fe203, As203, Sb203, Mn02, or a combination thereof, and wherein the one or more fining agents are present in a total amount equal to or less than about 1 mol %.
22. The glass-ceramic composition of any one of claims 1-21, further comprising one or more of coloring components selected from transition metal oxides and/or rare earth metal oxide, and wherein the one or more coloring components are present in a total amount equal to or less than about 1 mol%.
23. The glass-ceramic composition of any one of claims 1-22, further comprising a decolorizing agent comprising sodium sulphate, selenium compounds, erbium oxide, cerium oxide, cobalt oxide, manganese oxide, or any combination thereof.
24.The glass-ceramic composition of any one of claims 1-23, wherein the cornposition is ion-exchangeable.
25.A glass-ceramic composition comprising:
a) A1203 present from about 2 mol% to about 20 mol%, b) SiO2 present from about 48 mol% to about 80 mol%;
c) R'20 present from greater than 0 mol% to about 45 mol%; and wherein R'20 comprises U20, Na2O, K20, Ag2O, Cu2O, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase.
a) A1203 present from about 2 mol% to about 20 mol%, b) SiO2 present from about 48 mol% to about 80 mol%;
c) R'20 present from greater than 0 mol% to about 45 mol%; and wherein R'20 comprises U20, Na2O, K20, Ag2O, Cu2O, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a p-spodumene phase, and optionally, a petalite phase.
26. The glass-ceramic composition of claim 25, wherein when R'20 comprises Li20, the composition comprises a minor crystalline phase comprising a lithium silicate phase.
27. The glass-ceramic composition of claim 25 or 26, wherein A1203 is present from about 5 mol% to about 7.5 mol %, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of thep-spodumene phase and from about 20 to about 80% of the petalite phase.
28. The glass-ceramic composition of claim 26, wherein A1203 is present from about mol% to about 7.5 mol % and Li20 is present from 20 mol% to about 25 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase and from about 20 to about 80% of the petalite phase, and a minor phase comprises up to 10 mol% of the lithium silicate phase.
29. The glass-ceramic composition of claim 25 or 26, wherein A1203 is present from about 7 mol% to about 12 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the 0-spodumene phase.
30. The glass-ceramic composition of claim 26, wherein A1203 is present from about 7 mol% to about 12 mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the 13-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithiuni silicate phase.
31. The glass-ceramic composition of any one of claims 25-30, wherein the composition further comprises:
a) B203 present from 0 mol% to about 8 mol%, b) ZrO2from 0 mol% to about 8 mol%, and c) P205 from 0 mol% to about 5 mol%.
a) B203 present from 0 mol% to about 8 mol%, b) ZrO2from 0 mol% to about 8 mol%, and c) P205 from 0 mol% to about 5 mol%.
32. The glass-ceramic cornposition of any one of claims 25-31, wherein the composition is transparent, translucent, or opaque
33.The glass-ceramic composition of any one of claims 25-32, comprising a compressive stress layer.
34. The glass-ceramic cornposition of any one of claims 25-33, wherein the composition exhibits density from about 2.00 g/cm3 to about 2.6 g/cm3.
35. The glass-ceramic composition of any one of claims 32-34, wherein the composition is transparent and comprises a plurality of crystal grains, wherein the median size of a crystal grain is from about 20 to about 80 nm.
36. The glass-ceramic composition of any one of claims 32-34, wherein the composition is translucent and comprises a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 80 nm to about 500 nm.
37. The glass-ceramic composition of any one of claims 32-34, wherein the composition is opaque and comprises a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 500 nm.
38. The glass-ceramic composition of any one of claims 25-37, exhibiting Vickers hardness equal to or greater than about 6.0 GPa.
39. The glass-ceramic composition of any one of claims 25-38, exhibiting Vickers hardness of at least about 5% greater than Vickers hardness of a standard soda lime silicate glass.
40. The glass-ceramic composition of any one of claims 25-39, exhibiting a crack-resistance greater than about 0.2 kgf.
41.The glass-ceramic composition of any one of claims 25-40, exhibiting a crack-resistance greater than about 0.4 kgf.
42.The glass-ceramic composition of any one of claims 25-41, exhibiting a crack-resistance that at least 4 times higher than a crack-resistance of a standard soda lime silicate glass.
43. The glass-ceramic composition of any one of claims 25-42, exhibiting a thermal expansion coefficient from about 40x10.7 to about 90x10-7/oC.
44. The glass-ceramic cornposition of any one of claims 25-43, wherein the composition exhibits a glass transition temperature (TO from about 450 C to about 600 C.
45. The glass-ceramic composition of any one of claims 25-44, wherein the composition further comprises one or more fining agents selected from CeO2, Sn02, Fe203, As203, Sb203, Mn02, or a combination thereof, and wherein the one or more fining agents are present in a total amount equal to or less than about 1 mol %.
46. The glass-ceramic composition of any one of claims 25-45, wherein the cornposition further comprises a decolorizing agent comprising sodium sulphate, selenium compounds, erbium oxide, cerium oxide, cobalt oxide, manganese oxide, or any combination thereof.
47. The glass-ceramic composition of any one of claims 25-46, further comprising one or more coloring components selected from transition metal oxides and/or rare earth metal oxide, and wherein the one or more coloring components are present in a total amount equal to or less than about 1 mol%.
48.The glass-ceramic composition of any one of claims 25-47, wherein Ag20, and/or Cu2O, and/or CuO is present and wherein the glass-ceramic composition exhibits antimicrobial, antiviral, antibacterial, and/or antifungal properties.
49.A glass-ceramic article comprising the composition of any one of claims 1-48.
50.A glass-ceramic article comprising the composition of any one of claims 33-48, wherein the compressive stress layer extends from a surface of the article to a depth of the compressive stress layer, and wherein the depth is from about 1 pm to about 100 pm.
51.A glass-ceramic article comprising the composition of any one of claims 33-48, wherein the compressive stress layer extends from a surface of the article to a depth of the compressive stress layer, and wherein the depth is up to about 25 %
of a thickness of the glass-ceramic article.
of a thickness of the glass-ceramic article.
52.A glass-ceramic article comprising:
a) from about 2 mol% to about 20 mol% of A1203:
b) from about 2 mol% to about 45 mol% of Li20; and c) from about 48 mol% to about 80 mol% of Si02;
having a p-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase.
a) from about 2 mol% to about 20 mol% of A1203:
b) from about 2 mol% to about 45 mol% of Li20; and c) from about 48 mol% to about 80 mol% of Si02;
having a p-spodumene phase and a lithium silicate crystalline phase, and optionally a petalite phase.
53.A glass-ceramic article comprising:
a) A1202 present from about 2 mol% to about 20 mol%
b) SiO2 present from about 48 rnol% to about 80 rnol%. and c) R'20 present from greater than 0 mol% to about 45 mol%;
wherein R'20 comprises Li20, Na2O, K20, Ag2O, Cu20, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a fi-spodumene phase, and optionally, a petalite phase.
a) A1202 present from about 2 mol% to about 20 mol%
b) SiO2 present from about 48 rnol% to about 80 rnol%. and c) R'20 present from greater than 0 mol% to about 45 mol%;
wherein R'20 comprises Li20, Na2O, K20, Ag2O, Cu20, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a fi-spodumene phase, and optionally, a petalite phase.
54. The article of any one of claims 49-53, wherein the article comprises a hollowware, tableware, container, plate, sheet, float/flat sheet, cookware, powder, fiber, cones, spheres, blades, or any combination thereof.
55. The article of any one of claims 49-54, wherein the article is formed by a float or flat glass press process, a press-and-blow process, a blow-and-blow process, or any combination thereof.
56.A tableware comprising the composition of any one of claims 1-48.
57. The tableware of claim 56, wherein the tableware is formed by a press process, a press-and-blow process, and/or a blow-and-blow process.
58.A hollowware comprising the composition of any one of claims 1-48.
59.The hollowware of claim 57, wherein the hollowware is formed by a press process, a press-and-blow process, and/or a blow-and-blow process.
60.A powder comprising the composition of any one of claims 1-48.
61.A cookware comprising the composition of any one of claims 1-48.
62.The cookware of claim 61, wherein the cookware is formed by a press process, a press-and-blow process, and/or a blow-and-blow process.
63.A fiber comprising the composition of any one of claims 1-48.
64. The fiber of claim 63, wherein the fiber is formed by a continuous or discontinuous fiber drawing or spinning process.
65.A float/flat-glass-press product comprising the composition of any one of claims 1-48.
66.A press-and-blow product comprising the composition of any one of claims 1-48.
67.A blow-and-blow product comprising the composition of any one of claims 1-48.
68.A method comprising:
a) forming a mixture comprising:
from about 2 mol% to about 20 mol% of A1203.
from about 2 mol% to about 45 mol% of Li20; and from about 48 mol% to about 80 mol% of Si02:
b) forming a homogeneous composition; and c) ceramming the homogeneous composition to form a glass-ceramic composition.
a) forming a mixture comprising:
from about 2 mol% to about 20 mol% of A1203.
from about 2 mol% to about 45 mol% of Li20; and from about 48 mol% to about 80 mol% of Si02:
b) forming a homogeneous composition; and c) ceramming the homogeneous composition to form a glass-ceramic composition.
69. The method of claim 68, wherein the mixture further comprises from 0 mol%
to about 8 mol% of ZrO2, or from 0 mol% to about 5 mol% of P205, or a combination thereof.
to about 8 mol% of ZrO2, or from 0 mol% to about 5 mol% of P205, or a combination thereof.
70.The method of claim 68 or 69, wherein the step of forming the homogenous composition comprises melting the mixture in a furnace at a temperature from about 1,300 C to about 1,700 C for a first predetermined time.
71. The method of claim 70, further comprising a step of annealing at a temperature from about 450 "C to about 700
72. The method of any one of claims 68-71, wherein the step of ceramming cornprises heating the homogenous composition at a nucleation temperature for a second predetermined time.
73.The method of claim 72, wherein the nucleation temperature is from about to about 650 C.
74.The method of claim 71 or 72, wherein the step of ceramming further comprises a step of heating the composition to a crystallization temperature at a rate from about 5 C/min to about 15 C/min and keeping the composition at the crystallization temperature for a third predetermined time.
75. The method of claim 74, wherein the crystallization temperature is from about 580 C to about 800 C.
76. The method of any one of claims 74-75, wherein the first, the second, and/or the third predetermined times are from about 3 to 5 hours.
77.The method of any one of claims 72-76, wherein P205 is a nucleation agent.
78. The method of any one of claims 74-77, wherein ZrO2 is a crystal size growth-limiting agent.
79.The method of any one of claims 68-78, wherein the glass-ceramic composition comprises a j3-spoclumene phase, optionally petalite phase, and a lithium silicate crystalline phase.
80.The method of claim 79, wherein A1203 is present from about 5 mol% to about 7.5 mol %, the glass-ceramic composition comprises a major crystalline phase comprising from about 20 to about 80% of the p-spodumene phase and from about 20 to about 80% of the petalite phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
81.The method of claim 80, wherein Li20 is present in the composition from about 20 mol% to about 25 mol%.
82.The method of claim 81, wherein A1203 is present from about 7 mol% to about mol%, the glass-ceramic composition comprises a major crystalline phase comprising from about 60% to about 90% of the fi-spodumene phase and a minor crystalline phase comprising up to about 10% of the lithium silicate phase.
83. The method of any one of claims 80-82, wherein the lithium silicate crystalline phase comprises a lithium metasilicate crystalline phase.
84.The method of any one of claims 68-83, wherein the mixture further comprises a) from 0 mol% to about 8 mol% of B203, and b) from 0 mol% to about 8 mol% of Na20.
85. The method of any one of claims 68-84, further comprising a step of ion exchange treatment comprising exposure to a salt bath, spray, paste, a vapor-assisted ion exchange, a plasma-assisted ion exchange, or any combination thereof.
86. The method of claim 85, wherein the ion exchange treatment is electrically accelerated.
87. The method of claim 85 or 86, wherein the step of ion-exchange treatment comprises placing the glass-ceramic composition into a molten salt bath comprising sodium, potassium, silver, or copper (1) ions, or a combination thereof at conditions effective to provide an ion-exchanged glass-ceramic composition.
88. The method of clairn 87, wherein the ion-exchanged glass-ceramic composition comprises:
a) A1203 present from about 2 mol% to about 20 mol%;
b) SiO2 present from about 48 mol% to about 80 mol%.
c) R'20 present from greater than 0 mol% to about 45 mol%; and wherein R'20 comprises 1.120, Na20, K20, Ag20, Cu20, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a fi-spodumene phase, and optionally, a petalite phase.
a) A1203 present from about 2 mol% to about 20 mol%;
b) SiO2 present from about 48 mol% to about 80 mol%.
c) R'20 present from greater than 0 mol% to about 45 mol%; and wherein R'20 comprises 1.120, Na20, K20, Ag20, Cu20, CuO, or a combination thereof, wherein the composition comprises a major crystalline phase comprising a fi-spodumene phase, and optionally, a petalite phase.
89. The method of claim 87 or 88, wherein the conditions effective to provide the ion-exchanged glass-ceramic composition comprise exposure of the glass-ceramic cornposition to a molten salt at a temperature from about 380 C to about 500 C
for a time period from about 4 hours to about 20 hours.
for a time period from about 4 hours to about 20 hours.
90. The method of any one of claims 87-89, wherein the ion-exchanged glass-ceramic composition comprises a compressive stress layer.
91. The method of any one of claims 68-90, wherein the glass-cerarnic composition and/or the ion-exchanged glass-ceramic composition exhibit density from about 2.00 g/cm3 to about 2.6 g/cm3.
92.The method of any one of claims 68-91 wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit an average transmittance greater than about 80% over a wavelength range from about 390 nm to about 700 nm for a sample formed from the glass-ceramic and/or the ion-exchanged glass-ceramic composition and having a thickness of about 2.00 mm.
93. The method of any one of claims 68-92, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit an average transmittance between 20% and 80% over a wavelength range from about 390 nm to about 700 nm as measured for a sample formed from the glass-ceramic and/or the ion-exchanged glass-ceramic composition and having a thickness of about 2.00 mm.
94. The method of any one of claims 68-93, wherein the glass-ceramic cornposition and/or the ion-exchanged glass-ceramic composition exhibit an average transmittance lower than 20% over a wavelength range from about 390 nm to about 700 nm as measured for a sample formed from the glass-ceramic and/or the ion-exchanged glass-ceramic composition and having a thickness of about 2.00 mm.
95. The method of claim 94, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition comprise a plurality of crystal grains, wherein a size of a crystal grain is from about 20 to about 80 nm.
96.The method of claim 95, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition comprise a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 80 nm to about 500 nm.
97.The method of claim 96, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition comprise a plurality of crystal grains, wherein the median size of a crystal grain is from greater than about 500 nm.
98. The method of any one of claims 68-97, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit Vickers hardness equal to or greater than about 6.0 GPa.
99. The method of any one of claims 68-98, wherein the glass-ceramic cornposition and/or the ion-exchanged glass-ceramic composition exhibit Vickers hardness of at least about 5% greater than Vickers hardness of a composition comprising a standard soda lime silicate glass.
100. The method of any one of claims 68-99, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit a crack-resistance greater than about 0.2 kgf.
101. The method of any one of claims 68-100, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit a crack-resistance greater than 0.4 kgf.
102. The method of any one of claims 68-101, wherein the glass-ceramic composition exhibits a crack-resistance that at least 4 times higher than a crack -resistance of a composition comprising a standard soda lime silicate glass.
103. The method of any one of claims 68-102, wherein the glass-ceramic composition and/or the ion-exchanged glass-cerarnic composition exhibit a thermal expansion coefficient from about 40x1 0-7 to about 90x1 0-7 / C.
104. The method of any one of claims 68-103, wherein the glass-ceramic composition and/or the ion-exchanged glass-ceramic composition exhibit a glass transition temperature Tg from about 450 oC to about 600
105. The method of any one of claims 68-104 further comprising a step of forming a glass-ceramic article.
106. The method of claim 105, wherein the step of forming the glass-ceramic articles comprises a float or flat press process, a press-and-blow process, a blow-and-blow process, or any combination thereof.
107. The method of claim 105 or 106, wherein the glass-ceramic article comprises the ion-exchange composition and wherein the compressive stress layer extends frorn a surface of the article to a depth of the compressive stress layer, wherein the depth is from about 1 pm to about 100 pm.
108. The method of any one of claims 105-107, wherein the glass-ceramic article comprises the ion-exchange composition and wherein the compressive stress layer extends from a surface of the article to a depth of the compressive stress layer, and wherein the depth is up to about 25 % of a thickness of the glass-ceramic article.
109. The method of any one of claims 105-108, wherein the article comprises a hollowware, tableware, container, plate, sheet, float/flat sheet, cookware, powder, fiber, cones. spheres, blades, or any combination thereof.
110. A method of forming an article comprising forming a cornposition of any one of claims 1-48; and then forming the article, wherein the article comprises a hollowware, tableware, container, plate, sheet, float/flat sheet, cookware, powder, fiber, cones, spheres, blades, or any combination thereof.
111. The method of claim 110, wherein the step of forming comprises a float/flat press process, a press-and-blow process, a blow-and-blow process, or any combination thereof.
112. The method of claim 110 or 111, wherein the step of forming the composition comprises the method of any one of claims 68-104.
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US202063057404P | 2020-07-28 | 2020-07-28 | |
US63/057,404 | 2020-07-28 | ||
PCT/IB2021/056881 WO2022024007A1 (en) | 2020-07-28 | 2021-07-28 | Glass-ceramic compositions, articles, and methods of making the same |
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CA3172488A1 true CA3172488A1 (en) | 2022-02-03 |
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EP (1) | EP4188888A1 (en) |
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CN116102260A (en) * | 2022-12-14 | 2023-05-12 | 河北光兴半导体技术有限公司 | Transparent microcrystalline glass and preparation method and application thereof |
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JPS53112536A (en) | 1977-03-11 | 1978-10-02 | Nippon Electric Glass Co | Means for applying scorched pattern in electronic range |
US4461839A (en) | 1982-12-20 | 1984-07-24 | Corning Glass Works | Colored transparent, translucent and opaque glass-ceramics |
US4507392A (en) | 1983-12-08 | 1985-03-26 | Corning Glass Works | Transparent glass-ceramics of high negative expansion for use as decorative glazes |
JPS62182135A (en) | 1986-02-05 | 1987-08-10 | Nippon Electric Glass Co Ltd | Infrered-transparent glass ceramic and production thereof |
FR2946039A1 (en) | 2009-05-29 | 2010-12-03 | Eurokera | VITRO CERAMIC PLATE |
DE102011050867A1 (en) | 2011-06-06 | 2012-12-06 | Schott Ag | High-strength colored. smooth glass ceramic as a cooking surface on both sides |
CN104039729B (en) * | 2012-01-20 | 2016-12-07 | 斯特劳曼控股公司 | Prosthetic element |
US9701573B2 (en) | 2013-09-06 | 2017-07-11 | Corning Incorporated | High strength glass-ceramics having lithium disilicate and beta-spodumene structures |
ES2840674T3 (en) | 2014-10-08 | 2021-07-07 | Corning Inc | High-strength glass-ceramics that have lithium silicate and petalite structures |
US10723649B2 (en) * | 2017-11-30 | 2020-07-28 | Corning Incorporated | Black lithium silicate glass ceramics |
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2021
- 2021-07-28 BR BR112023001555A patent/BR112023001555A2/en unknown
- 2021-07-28 AU AU2021317101A patent/AU2021317101A1/en active Pending
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CN115836034A (en) | 2023-03-21 |
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JP2023538795A (en) | 2023-09-12 |
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AU2021317101A1 (en) | 2022-09-22 |
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